Article of footwear with outsole bonded to cushioning component and method of manufacturing an article of footwear

ABSTRACT

An article of footwear comprises a sole structure having a cushioning component defining an enclosed, fluid-filled chamber. The cushioning component has a top wall, a bottom wall, a medial side wall at a medial side of the article of footwear, and a lateral side wall at a lateral side of the article of footwear. The cushioning component includes a unitary outsole having a bottom portion, a medial side portion, and a lateral side portion. The bottom portion is bonded to the bottom wall, the medial side portion is bonded to the medial side wall, and the lateral side portion is bonded to the lateral side wall. A method of manufacturing includes disposing the first and second polymer sheets and the outsole in a mold assembly and thermally bonding the outsole to the second polymer sheet, and the first and second polymer sheets to one another to form a chamber.

TECHNICAL FIELD

The present teachings generally include an article of footwear with acushioning component and an outsole.

BACKGROUND

Conventional articles of athletic footwear include two primary elements,an upper and a sole structure. The upper is generally formed from aplurality of elements (e.g., textiles, foam, leather, synthetic leather)that are stitched or adhesively bonded together to form an interior voidfor securely and comfortably receiving a foot. The sole structureincorporates multiple layers that are conventionally referred to as asockliner, a midsole, and an outsole. The sockliner is a thin,compressible member located within the void of the upper and adjacent toa plantar (i.e., lower) surface of the foot to enhance comfort. Themidsole is secured to the upper and forms a middle layer of the solestructure that attenuates ground reaction forces (i.e., impartscushioning) during walking, running, or other ambulatory activities. Theoutsole forms a ground-contacting element of the footwear and is usuallyfashioned from a durable and wear-resistant rubber material thatincludes texturing to impart traction.

The primary material forming many conventional midsoles is a polymerfoam, such as polyurethane or ethylvinylacetate. In some articles offootwear, the midsole may also incorporate a fluid-filled chamber thatincreases durability of the footwear and enhances ground reaction forceattenuation of the sole structure. In some footwear configurations, thefluid-filled chamber may be at least partially encapsulated within thepolymer foam, as in U.S. Pat. No. 5,755,001 to Potter, et al., U.S. Pat.No. 6,837,951 to Rapaport, and U.S. Pat. No. 7,132,032 to Tawney, et al.In other footwear configurations, the fluid-filled chamber maysubstantially replace the polymer foam, as in U.S. Pat. No. 7,086,180 toDojan, et al. In general, the fluid-filled chambers are formed from apolymer material that is sealed and pressurized, but may also besubstantially unpressurized or pressurized by an external source. Insome configurations, textile or foam tensile members may be locatedwithin the chamber, or reinforcing structures may be bonded to anexterior surface of the chamber to impart shape to or retain an intendedshape of the chamber.

Fluid-filled chambers suitable for footwear applications may bemanufactured through various processes, including a two-film technique,thermoforming, and blowmolding. In the two-film technique, two planarsheets of polymer material are bonded together in various locations toform the chamber. In order to pressurize the chamber, a nozzle or needleconnected to a fluid pressure source is inserted into a fill inletformed in the chamber. Following pressurization, the fill inlet issealed and the nozzle is removed. Thermoforming is similar to thetwo-film technique, but utilizes a heated mold that forms or otherwiseshapes the sheets of polymer material during the manufacturing process.In blowmolding, a molten or otherwise softened elastomeric material inthe shape of a tube (i.e., a parison) is placed in a mold having thedesired overall shape and configuration of the chamber. The mold has anopening at one location through which pressurized air is provided. Thepressurized air induces the liquefied elastomeric material to conform tothe shape of the inner surfaces of the mold, thereby forming thechamber, which may then be pressurized.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is lateral side elevational view of an article of footwear.

FIG. 2 is a medial side elevational view of the article of footwear.

FIGS. 3A and 3B are cross-sectional views of the article of footwear, asdefined by section lines 3A and 3B in FIGS. 1 and 2

FIG. 4 is a perspective view of a forefoot component of the solestructure.

FIG. 5 is a top plan view of the forefoot component.

FIG. 6 is a bottom plan view of the forefoot component.

FIG. 7 is a lateral side elevational view of the forefoot component.

FIG. 8 is a medial side elevational view of the forefoot component.

FIGS. 9A-9E are cross-sectional views of the forefoot component, asdefined by section lines 9A-9E in FIG. 5.

FIGS. 10A-10E are top plan views corresponding with FIG. 5 and depictingfurther configurations of the forefoot component.

FIGS. 11A-11E are cross-sectional views corresponding with FIG. 9A anddepicting further configurations of the forefoot component.

FIG. 12 is a perspective view of a heel component of the sole structure.

FIG. 13 is a top plan view of the heel component.

FIG. 14 is a bottom plan view of the heel component.

FIG. 15 is a lateral side elevational view of the heel component.

FIG. 16 is a medial side elevational view of the heel component.

FIGS. 17A and 17B are cross-sectional views of the heel component, asdefined by section lines 17A and 17B in FIG. 13.

FIGS. 18A-18C are cross-sectional views corresponding with FIG. 17A anddepicting further configurations of the heel component.

FIGS. 19A-19C are cross-sectional views corresponding with FIG. 17B anddepicting further configurations of the heel component.

FIGS. 20 and 21 are perspective views of a forefoot component mold.

FIGS. 22A-22E are cross-sectional views depicting a manufacturingprocess for forming the forefoot component utilizing the forefootcomponent mold, as defined along a section line 22 in FIGS. 20 and 21.

FIGS. 23 and 24 are perspective views of a heel component mold.

FIGS. 25A-25D are cross-sectional views depicting a manufacturingprocess for forming the heel component utilizing the heel componentmold, as defined along a section line 25 in FIGS. 23 and 24.

FIG. 26A is a cross-sectional view corresponding with FIG. 17A anddepicting another configuration of the heel component.

FIG. 26B is an exploded cross-sectional view of the configuration fromFIG. 26A.

FIG. 27 is a schematic perspective illustration of another configurationof an article of footwear and showing a lateral side and a bottom.

FIG. 28 is a schematic perspective illustration of the article offootwear of FIG. 27 and showing a medial side.

FIG. 29 is a schematic cross-sectional illustration of the article offootwear of FIG. 27 taken at lines 29-29 in FIG. 27.

FIG. 30 is a schematic cross-sectional illustration of the article offootwear of FIG. 27 taken at lines 30-30 in FIG. 27.

FIG. 31 is a schematic perspective illustration of another configurationof an article of footwear.

FIG. 32 is a schematic illustration in exploded cross-sectional view ofa sole structure of the article of footwear of FIG. 27 and a moldassembly for a manufacturing process.

FIG. 33 is a schematic illustration in a lateral side elevational viewof an embodiment of an article of footwear.

FIG. 34 is a schematic illustration in bottom view of the article offootwear of FIG. 33.

FIG. 35 is a cross-sectional view of the article of footwear of FIG. 34.

FIG. 36 is a schematic illustration in bottom view of a forefoot solestructure of an article of footwear.

FIG. 37 is a schematic illustration in bottom perspective view of aforefoot outsole of FIG. 34.

FIG. 38 is a schematic illustration in an exploded view illustrating arelationship between a forefoot outsole and a forefoot component thatform a forefoot sole structure of FIG. 34.

FIG. 39 is a schematic illustration in an exploded view illustrating arelationship between a heel outsole and a heel component that form aheel sole structure of FIG. 34.

FIG. 40 is a schematic illustration in an exploded view illustrating arelationship between a forefoot outsole and a forefoot component thatform a forefoot sole structure of FIG. 36.

FIG. 41 is a schematic illustration in a cross-sectional view of an openmold illustrating a relationship of the parts for forming a forefootsole structure of FIG. 36 in the mold.

FIG. 42 is a schematic illustration in a cross-sectional view of aclosed mold illustrating a forefoot sole structure of FIG. 36 formed inthe mold.

FIG. 43 is a schematic illustration in a cross-sectional view of an openmold illustrating the relationship of the parts for forming a heel solestructure like that of FIG. 33 in the mold.

FIG. 44 is a schematic illustration in cross-sectional view of apartially-formed heel sole structure of FIG. 43 in a partially-openmold.

FIG. 45 is a schematic illustration in cross-sectional view of a closedmold illustrating the heel sole structure of FIG. 44 formed in the mold.

FIG. 46 is a schematic illustration in cross-sectional view of a heelsole structure of FIG. 45 removed from the opened mold after forming thestructure.

FIG. 47 is a schematic illustration in cross-sectional view of anembodiment of a heel sole structure.

FIG. 48 is a schematic illustration in cross-sectional view of anotherembodiment of a heel sole structure.

FIG. 49 is a schematic illustration in cross-sectional view of stillanother embodiment of a heel sole structure.

FIG. 50 is a schematic illustration in bottom view of an embodiment ofan article of footwear;

FIG. 51 is a schematic illustration in cross-sectional view of an openmold illustrating a relationship of parts for producing an article.

FIG. 52 is a schematic illustration in cross-sectional view of a closedmold illustrating a relationship of parts for producing the article ofFIG. 51.

FIG. 53 is a schematic lateral side view illustration of anotherconfiguration of an article of footwear with an upper shown in phantom.

FIG. 54 is a schematic medial side view illustration of the article offootwear of FIG. 53.

FIG. 55 is a schematic rear view illustration of the article of footwearof FIGS. 53 and 54.

DESCRIPTION

An article of footwear is provided that comprises a sole structurehaving a cushioning component defining an enclosed, fluid-filledchamber. The cushioning component has a top wall, a bottom wall, amedial side wall, and a lateral side wall. The cushioning componentincludes a unitary outsole having a bottom portion, a medial sideportion, and a lateral side portion. The bottom portion is bonded to thebottom wall, the medial side portion is bonded to the medial side wall,and the lateral side portion is bonded to the lateral side wall of thecushioning component. The unitary outsole thus wraps around thecushioning component by extending at least partially up the sideportions from the bottom portion. The unitary outsole may also haveintegral tread portions on the bottom portion.

The bottom wall of the cushioning component may have a heel portion, amidfoot portion, and a forefoot portion. The bottom portion of theoutsole may be coextensive with the bottom wall of the cushioningcomponent.

In an embodiment, the cushioning component includes a first polymersheet, and a second polymer sheet bonded to the first polymer sheet sothat the first and second polymer sheets form a peripheral flange anddefine the fluid-filled chamber. The first polymer sheet includes thetop wall, and the second polymer sheet includes the bottom wall, themedial side wall and the lateral side wall. The peripheral flange isnearer the top wall than the bottom wall.

The first polymer sheet and the second polymer sheet may be a variety ofmaterials, such as multi-layer polymer sheets including thermoplasticpolyurethane layers alternating with barrier layers that comprise acopolymer of ethylene and vinyl alcohol (EVOH) impermeable to fluidcontained in the chamber.

The cushioning component may include a tether element joined to an innersurface of the top wall and to an inner surface of the bottom wallwithin the chamber. The tether element may be any of variousconfigurations. In an embodiment, the tether element includes a firstplate bonded to the inner surface of the top wall, a second plate bondedto the inner surface of the bottom wall, and a plurality of tetherssecured to the first plate and to the second plate and extending in thefluid-filled chamber between the first plate and the second plate. Thefluid-filled chamber may be pressurized by fluid in the chamber to placethe tethers in tension.

In an embodiment, the cushioning component has a midfoot portion and aheel portion rearward of the midfoot portion. At least one of thelateral side portion and the medial side portion forms at least one peakdisposed at or rearward of the midfoot portion and at least one valleydisposed rearward of the at least one peak. The peak may be at leastpartially aligned with the tether element. In one embodiment, thecushioning component is substantially transparent. This allows thetethers to be viewed through the valley. Additionally, the outsole maybe substantially transparent, such as a substantially transparentthermoplastic polyurethane. In such an embodiment, the tethers may beviewed both through the valley and through the peak.

The at least one peak may include multiple peaks and the at least onevalley may include multiple valleys, with the peaks and the valleysarranged in alternating order such that the peaks are spaced apart fromone another by the valleys. Additionally, the peaks may vary in height.For example, the cushioning component may have a heel portion, a midfootportion, and a forefoot portion. A first one of the peaks may be at theheel portion and have a first height, and a second one of the peaks maybe at the forefoot portion and have a second height less than the firstheight. A third one of the peaks may be at the midfoot portion and havea third height less than the second height. In an embodiment, the peaksand the valleys are fingers and notches, respectively.

The article of footwear may include an additional footwear component,such as an upper, that has a bottom surface, a lateral surface, and amedial surface. The bottom surface may be supported on the top wall ofthe cushioning component. The peripheral flange of the cushioningcomponent may be bonded to the lateral surface and the medial surface ofthe additional footwear component. Accordingly, the outsole cups thecushioning component by wrapping at least partially up the sides of thecushioning component, and the peripheral flange of the cushioningcomponent cups the additional footwear component by wrapping at leastpartially up the sides of the additional footwear component.

A method of manufacturing an article of footwear includes disposingfirst and second polymer sheets in a mold assembly, and disposing apreformed unitary outsole in the mold assembly adjacent the secondpolymer sheet. The preformed unitary outsole has a bottom portion, amedial side portion, and a lateral side portion, and may be preformedsuch as by injection molding. The method includes closing the moldassembly to compress the first and second polymer sheets and theoutsole, and thermally bonding the first and second polymer sheets, andthe outsole to one another in the mold assembly. The first and secondpolymer sheets are bonded to one another to form a cushioning componentwith a chamber. The cushioning component has a top wall, a bottom wall,a medial side wall, and a lateral side wall. The bottom portion of theoutsole is bonded to the bottom wall, the medial portion of the outsoleis bonded to the medial side wall, and the lateral side portion of theoutsole is bonded to the lateral side wall.

In an embodiment, the cushioning component has a midfoot portion and aheel portion rearward of the midfoot portion, and at least one of thelateral side portion and the medial side portion forms at least one peakdisposed at or rearward of the midfoot portion and at least one valleydisposed rearward of the at least one peak. In such an embodiment,disposing the preformed unitary outsole adjacent the second polymersheet may include aligning the at least one peak with the tetherelement.

In an embodiment, thermally bonding the first and second polymer sheetsto one another in the mold assembly comprises establishing a peripheralflange, and the method further includes bonding the peripheral flange toside surfaces of an additional footwear component, such as an upper.

The method may include thermoforming the first and second polymer sheetsin the mold assembly, such as to conform to shapes of the mold portions.The method may further include vacuum forming the first and secondpolymer sheets in the mold assembly, such as to draw the first polymersheet against the surface of a portion of the mold and to draw thesecond polymer sheet against the outsole.

In an embodiment, the method includes disposing a tether element in amold assembly between a first polymer sheet and a second polymer sheet.The chamber contains the tether element, and the tether element isbonded to inner surfaces of the first and second polymer sheets. Thetether element may include a first plate thermally bonded to the topwall, a second plate thermally bonded to the bottom wall, and aplurality of tethers secured to the first plate and to the second plateand extending in the chamber between the first plate and the secondplate. Thermally bonding the tether element to inner surfaces of thefirst and second polymer sheets may be simultaneous with thermallybonding the first and second polymer sheets to one another to establisha peripheral flange. The method may include inflating the chamber toplace the tethers in tension.

The above features and advantages and other features and advantages ofthe present teachings are readily apparent from the following detaileddescription of the modes for carrying out the present teachings whentaken in connection with the accompanying drawings.

“A,” “an,” “the,” “at least one,” and “one or more” are usedinterchangeably to indicate that at least one of the items is present. Aplurality of such items may be present unless the context clearlyindicates otherwise. All numerical values of parameters (e.g., ofquantities or conditions) in this specification, unless otherwiseindicated expressly or clearly in view of the context, including theappended claims, are to be understood as being modified in all instancesby the term “about” whether or not “about” actually appears before thenumerical value. “About” indicates that the stated numerical valueallows some slight imprecision (with some approach to exactness in thevalue; approximately or reasonably close to the value; nearly). If theimprecision provided by “about” is not otherwise understood in the artwith this ordinary meaning, then “about” as used herein indicates atleast variations that may arise from ordinary methods of measuring andusing such parameters. In addition, a disclosure of a range is to beunderstood as specifically disclosing all values and further dividedranges within the range.

The terms “comprising,” “including,” and “having” are inclusive andtherefore specify the presence of stated features, steps, operations,elements, or components, but do not preclude the presence or addition ofone or more other features, steps, operations, elements, or components.Orders of steps, processes, and operations may be altered when possible,and additional or alternative steps may be employed. As used in thisspecification, the term “or” includes any one and all combinations ofthe associated listed items. The term “any of” is understood to includeany possible combination of referenced items, including “any one of” thereferenced items. The term “any of” is understood to include anypossible combination of referenced claims of the appended claims,including “any one of” the referenced claims.

Those having ordinary skill in the art will recognize that terms such as“above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are useddescriptively relative to the figures, and do not represent limitationson the scope of the invention, as defined by the claims.

The following discussion and accompanying figures disclose variousfluid-filled chambers. Concepts related to the chambers are disclosedwith reference to footwear that is suitable for running. The chambersare not limited to footwear designed for running, however, and may beutilized with a wide range of athletic footwear styles, includingbasketball shoes, cross-training shoes, cycling shoes, football shoes,soccer shoes, tennis shoes, and walking shoes, for example. Variousconfigurations of the chambers may be utilized with footwear styles thatare generally considered to be non-athletic, including dress shoes,loafers, sandals, and boots. Accordingly, concepts related to thechambers may apply to a wide variety of footwear styles.

General Footwear Structure

An article of footwear 10 is depicted in FIGS. 1 and 2 as including anupper 20 and a sole structure 30. Upper 20 provides a comfortable andsecure covering for a foot of a wearer. As such, the foot may be locatedwithin upper 20 to effectively secure the foot within footwear 10 orotherwise unite the foot and footwear 10. Sole structure 30 is securedto a lower area of upper 20 and extends between the foot and the groundto attenuate ground reaction forces (i.e., cushion the foot), providetraction, enhance stability, and influence the motions of the foot, forexample. In effect, sole structure 30 is located under the foot andsupports the foot.

For reference purposes, footwear 10 may be divided into three generalregions: a forefoot region 11, a midfoot region 12, and a heel region13. Forefoot region 11 generally includes portions of footwear 10corresponding with toes of the foot and the joints connecting themetatarsals with the phalanges. Midfoot region 12 generally includesportions of footwear 10 corresponding with an arch area of the foot.Heel region 13 generally corresponds with rear portions of the foot,including the calcaneus bone. Footwear 10 also includes a lateral side14 and a medial side 15, which correspond with opposite sides offootwear 10 and extend through each of regions 11-13. More particularly,lateral side 14 corresponds with an outside area of the foot (i.e. thesurface that faces away from the other foot), and medial side 15corresponds with an inside area of the foot (i.e., the surface thatfaces toward the other foot). Regions 11-13 and sides 14-15 are notintended to demarcate precise areas of footwear 10. Rather, regions11-13 and sides 14-15 are intended to represent general areas offootwear 10 to aid in the following discussion. In addition to footwear10, regions 11-13 and sides 14-15 may also be applied to upper 20, solestructure 30, and individual elements thereof.

Upper 20 is depicted as having a substantially conventionalconfiguration. A majority of upper 20 incorporates various materialelements (e.g., textiles, foam, leather, and synthetic leather) that arestitched or adhesively bonded together to form an interior void forsecurely and comfortably receiving a foot. The material elements may beselected and located in upper 20 to selectively impart properties ofdurability, air-permeability, wear-resistance, flexibility, and comfort,for example. The void in upper 20 is shaped to accommodate the foot.When the foot is located within the void, therefore, upper 20 extendsalong a lateral side of the foot, along a medial side of the foot, overthe foot, around the heel, and under the foot. An ankle opening 21 inheel region 13 provides the foot with access to the void. A lace 22extends over a tongue 23 and through various lace apertures 24 or otherlace-receiving elements in upper 20. Lace 22 and the adjustabilityprovided by tongue 23 may be utilized in a conventional manner to modifythe dimensions of ankle opening 21 and the interior void, therebysecuring the foot within the interior void and facilitating entry andremoval of the foot from the interior void. As depicted in FIGS. 3A and3B, upper 20 also includes a sockliner 25 that is located within thevoid and positioned to extend under a lower surface of the foot toenhance the comfort of footwear 10. Further configurations of upper 20may also include one or more of (a) a toe guard positioned in forefootregion 11 and formed of a wear-resistant material, (b) a heel counterlocated in heel region 13 for enhancing stability, and (c) logos,trademarks, and placards with care instructions and materialinformation. Given that various aspects of the present discussionprimarily relate to sole structure 30, upper 20 may exhibit the generalconfiguration discussed above or the general configuration ofpractically any other conventional or non-conventional upper.Accordingly, the structure of upper 20 may vary significantly within thescope of the present disclosure.

The primary elements of sole structure 30 are a forefoot component 40, aheel component 50, and an outsole 60. Each of components 40 and 50 aredirectly secured to a lower area of upper 20 and formed from a polymermaterial that encloses a fluid, which may be a gas, liquid, or gel.During walking and running, for example, components 40 and 50 compressbetween the foot and the ground, thereby attenuating ground reactionforces. That is, components 40 and 50 are inflated and generallypressurized with the fluid to cushion the foot. Outsole 60 is secured tolower areas of components 40 and 50 and may be formed from awear-resistant rubber material that is textured to impart traction. Insome configurations, sole structure 30 may include a foam layer, forexample, that extends between upper 20 and one or both of components 40and 50, or a foam element may be located within indentations in thelower areas of components 40 and 50. In other configurations, solestructure 30 may incorporate plates, moderators, lasting elements, ormotion control members that further attenuate forces, enhance stability,or influence the motions of the foot.

Forefoot Component

Forefoot component 40 is depicted separate from footwear 10 in FIGS. 4-8and is formed from a polymer material that defines a first or uppersurface 41 and an opposite second or lower surface 42. Whereas uppersurface 41 is secured to upper 20, different portions of lower surface42 are either secured to outsole 60 or exposed and visible from anexterior surface of footwear 10. As described in greater detail below,upper surface 41 and lower surface 42 are formed from polymer layersduring a molding or thermoforming process. More particularly, uppersurface 41 is formed from one polymer layer, and lower surface 42 isformed from another polymer layer.

Forefoot component 40 includes a plurality of chambers 43 a-43 f, aflange 44, a web area 45, and various conduits 46. Chambers 43 a-43 fenclose or contain the fluid within forefoot component 40. Moreparticularly, chambers 43 a-43 f are areas of forefoot component 40where the polymer layers forming surfaces 41 and 42 are separated orspaced from each other to form voids for enclosing the fluid withinforefoot component 40. Flange 44 extends around a peripheral area offorefoot component 40 and is formed from portions of the polymer layersthat are molded and joined together. Web area 45 extends through acentral area of forefoot component 40 and between the various chambers43. Like flange 44, web area 45 is formed from portions of the polymerlayers that are joined together. Although adhesive bonding may beutilized in joining the polymer layers in flange 44 and web area 45,thermal bonding may also join the polymer layers during the molding orthermoforming process. Conduits 46 extend between chambers 43 a-43 f andform channels that place chambers 43 a-43 f in fluid communication. Thatis, the fluid within forefoot component 40 may be transferred betweenchambers 43 a-43 f by passing through conduits 46. Like chambers 43 a-43f, conduits 46 are formed from separated or spaced portions of thepolymer layers forming surfaces 41 and 42.

Chambers 43 a-43 f are the primary components of forefoot component 40that enclose the fluid. In areas immediately adjacent to each ofchambers 43 a-43 f, the polymer layers forming surfaces 41 and 42 arejoined to each other to form a bond that seals the fluid within forefootcomponent 40. More particularly, flange 44 and web area 45 cooperativelybound or otherwise extend around each of chambers 43 a-43 f and areformed from areas of the polymer layers that are bonded to each other,thereby sealing the fluid within chambers 43. Although chambers 43 a-43f effectively contain the fluid within forefoot component 40, each ofchambers 43 a-43 f are placed in fluid communication through conduits46. In further configurations of footwear 10, however, one or more ofconduits 46 may be absent to segregate the fluid in one of chambers 43a-43 f from the fluid in another one of chambers 43 a-43 f, and thefluids may be pressurized differently. In other configurations, forefootcomponent 40 may be a part of a fluid system that, for example, pumpsfluid into chambers 43 a-43 f to tailor the pressure within forefootcomponent 40 to the preferences or running style of the wearer.

Upper surface 41 has a generally concave, rounded, and relatively smoothconfiguration that supports the foot when footwear 10 is worn. Referringto the cross-sections of FIGS. 9A-9C, for example, the roundedconfiguration of upper surface 41 lays on a curved plane that iscooperatively formed by chambers 43 a-43 f, flange 44, web area 45, andconduits 46. In contrast, lower surface 42 is more contoured, withchambers 43 a-43 f extending or protruding downward from flange 44 andweb area 45. In effect, therefore, the portions of chambers 43 a-43 fthat protrude downward form independent supports or cushioning elementsin sole structure 30.

Undulations or other discontinuities in first surface 41, which supportsthe foot, that are greater than one millimeter may decrease footwearcomfort. The pressure of the fluid within chambers 43 a-43 f tends topress outward upon the polymer layers forming surfaces 41 and 42, whichcauses areas of forefoot component 40 corresponding with chambers 43a-43 f to bulge or protrude outward. Although first surface 41 mayexhibit some undulations adjacent to chambers 43 a-43 f, the size ofthese undulations is generally limited to less than one millimeter,thereby enhancing the comfort of footwear 10.

Various features of forefoot component 40 operate cooperatively to limitthe size of the undulations in first surface 41, including (a) athickness of the polymer material forming chambers 43 a-43 f, (b) thepressure of the fluid within chambers 43 a-43 f, and (c) the width ofchambers 43 a-43 f between spaced portions of web area 45. In general,as the thickness of the polymer material forming chambers 43 a-43 fincreases, or as the pressure of the fluid within chambers 43 a-43 fdecreases, the degree to which chambers 43 a-43 f bulge or protrudeoutward and form undulations decreases. For footwear applications, apolymer thickness of 0.75 millimeter (0.03 inch) and a fluid pressure of138 kilopascals (20 pounds per square inch) provides a suitable degreeof compliance, force attenuation, and other properties. Given thisthickness and pressure, having a maximum width of less than 14millimeters, and possibly less than 12 millimeters, in chambers 43 a-43f limits the size of undulations in first surface 41 to less than onemillimeter.

A width dimension 47 is depicted in FIGS. 5, 6, and 9D as extending (a)across various portions of chambers 43 a-43 f, (b) between spacedportions of web area 45, and (c) in a direction that is generallyparallel to the most proximal area of first surface 41. Chambers 43 a-43f have E-shaped and C-shaped configurations. Whereas some areas ofchambers 43 a-43 f are located adjacent to flange 44, other areas ofchambers 43 a-43 f extend inward and toward a central area of forefootcomponent 40. In the example of subchambers 43 b and 43 e, which areE-shaped, each has three parallel and generally linear segments thatextend inward and are bounded on opposite sides by portions of web area45. As such, width dimension 47 may be measured between the spacedportions of web area 45 that are located on opposite sides of the threeparallel segments. In the example of subchambers 43 c and 43 f, whichare also E-shaped, each has two parallel and generally linear segmentsthat extend inward and are bounded by web area 45. As such, widthdimension 47 may be measured between the spaced portions of web area 45that are located on opposite sides of two parallel segments. In theexample of subchambers 43 a and 43 d, which are C-shaped, each has onegenerally curved segment that extends inward and is bounded by web area45. As such, width dimension 47 may be measured between the spacedportions of web area 45 that are located on opposite sides of thesegments. Note that portions of subchambers 43 a-43 f that areimmediately adjacent to flange 44 may also have a maximum width of lessthan 14 millimeters, and possibly less than 12 millimeters, but may alsohave a maximum width greater than 14 millimeters.

In addition to E-shaped and C-shaped configurations, any of chambers 43a-43 f may be structured to have F, H, I, J, K, L, M, N, S, T, U, V, W,X, and Y-shaped configurations, in addition to various other shapes,whether following letters of the alphabet or being non-regular. Ingeneral, however, one or more of chambers 43 a-43 f will have a shapeformed from relatively narrow and elongate segments having a maximumwidth of less than 14 millimeters, and possibly less than 12millimeters. Moreover, these segments will extend into a central area offorefoot component 40 and be bounded on opposite sides by portions ofweb area 45.

Although width dimension 47 of chambers 43 a-43 f may be limited to lessthan 14 or 12 millimeters, the height and length of the various segmentsforming chambers 43 a-43 f may vary considerably. In general and withall other factors being the same, as the volume of each of chambers 43a-43 f increases, the degree of cushioning or force attenuation providedby forefoot component 40 also increases. By maximizing the heights andlengths of portions or segments in chambers 43 a-43 f, cushioning orforce attenuation properties may also be enhanced. As an example, insome configurations of forefoot component 40, the height of chambers 43a-43 f may be more than fourteen millimeters, with the height beingmeasured in a direction that is perpendicular to the width dimension 47and at a location of width dimension 47.

Chambers 43 are located along or adjacent to opposite sides of forefootcomponent 40. When incorporated into footwear 10, a first group ofchambers 43 a-43 c are located on lateral side 14 and a second group ofchambers 43 d-43 f are located on medial side 15. In effect, therefore,the two groups are located adjacent to sides 14 and 15, and web area 45extends between the groups. In other configurations of forefootcomponent 40, however, chambers 43 may be positioned in otherarrangements or locations within forefoot component 40. One or more ofchambers 43 may also extend between opposite sides of forefoot component40, rather than being positioned adjacent to one side of forefootcomponent 40.

Flange 44 forms a peripheral seam or bonded area that joins the polymerlayers forming surfaces 41 and 42 and assists with sealing the fluidwithin forefoot component 40 and the voids of chambers 43 a-43 f. Ingeneral, flange 44 has a height of at least five millimeters and extendsin an outward direction from a remainder of forefoot component 40.Relative to the voids within chambers 43 a-43 f flange 44 extendsoutward from the voids. More particularly, flange 44 extends in anupward direction from the peripheral area or an upper area of forefootcomponent 40. Whereas the area of flange 44 corresponding with firstsurface 41 faces toward and is secured to upper 20, the area of flange44 corresponding with second surface 42 faces away from and forms aportion of an exterior surface of footwear 10. More simply, one surfaceof flange 44 is secured to upper 20, and the opposite surface of flange44 faces away from upper 20. Given that flange 44 is a relatively thickand stiff portion of forefoot component 40, flange 44 may enhance thestability of footwear 10. Flange 44 may also provide a defined lastingmargin during steps of the manufacturing process that involve bondingupper 20 to forefoot component 40.

Referring to the cross-sections of FIGS. 9A and 9B, for example, flange44 is depicted as having a tapered configuration, with the portions offlange 44 located adjacent to the voids in chambers 43 a-43 f havinggreater thickness than the portions of flange 44 that are spaced fromthe voids and form a distal end. In effect, therefore, flange 44 has atapered configuration with a first thickness adjacent to the voids and asecond thickness spaced away from the voids, the first thickness beinggreater than the second thickness. Moreover, thickness of the portionsof flange 44 located adjacent to the voids (i.e., the first thickness)is greater than either of (a) the thickness of web area 45 in thecentral area of forefoot component 40 and (b) the sum of the thicknessesof the polymer layers forming surfaces 41 and 42. Although flange 44 isformed from the polymer layers forming surfaces 41 and 42 and web area45, flange 44 has a greater thickness than both of the polymer layerscombined. As noted above, flange 44 is a relatively thick and stiffportion of forefoot component 40. A portion of the stiffness may be due,therefore, to the greater thickness of flange 44 adjacent to chambers 43a-43 f. A process for forming flange 44 to have this configuration willbe discussed below.

Although flange 44 is present in areas adjacent to chambers 43 a-43 fflange 44 is depicted as being absent or having minimal height andthickness in areas between chambers 43 a-43 f as depicted in FIGS. 9Cand 9E. This configuration provides enhanced flexibility to forefootcomponent 40. More particularly, given that flange 44 is a relativelythick and stiff portion of forefoot component 40, areas where flange 44are absent or minimized may have greater flexibility.

Web area 45 extends throughout a central area of forefoot component 40to separate and interconnect the various chambers 43 a-43 f. In thisposition, web area 45 forms a bonded area that joins the polymer layersforming surfaces 41 and 42 and also assists with sealing the fluidwithin the voids of chambers 43 a-43 f. Whereas chambers 43 a-43 fprotrude outward to form structures for receiving the fluid withinforefoot component 40, web area 45 exhibits lesser thickness to provideflexibility in forefoot component 40 and permit each of chambers 43 a-43f to move or deflect independently in footwear 100. As noted above,flange 44 may be absent or have minimal height and thickness in areasbetween chambers 43 a-43 f, thereby further contributing to flexibilityin forefoot component 40.

Various factors may be considered when selecting materials for forefootcomponent 40, including each of polymer layers 41 and 42. As an example,the engineering properties of the materials (e.g., tensile strength,tear strength, flexural fatigue strength, modulus of elasticity, andabrasion resistance) may be considered. The ability of the materials tobe shaped into chambers 43 a-43 f and bonded to form flange 44 and webarea 45 during the manufacture of forefoot component 40 may also beconsidered. Additionally, the ability of the materials to prevent thetransmission (e.g., diffusion, permeation) of the fluid contained byforefoot component 40 may be considered. Suitable materials for forefootcomponent 40 include a variety of thermoset and thermoplastic polymermaterials. An advantage of thermoplastic polymer materials is that theymay be molded (e.g., thermoformed) to impart the shapes of chambers 43a-43 f and flange 44. Moreover, thermoplastic polymer materials may bethermal bonded to each other to form flange 44 and web area 45. Giventhese considerations, examples of polymer materials that may be utilizedfor forefoot component 40 include any of the following: polyurethane,urethane, polyester, polyester polyurethane, polyether, polyetherpolyurethane, latex, polycaprolactone, polyoxypropylene, polycarbonatemacroglycol, and mixtures thereof.

Although any of the materials noted above may be utilized for forefootcomponent 40, various materials exhibit both diffusion-prevention andthermoplastic properties. An example of this material is disclosed inU.S. Pat. Nos. 5,713,141 and 5,952,065 to Mitchell, et al., both ofwhich are incorporated herein by reference. Although variousconfigurations may be utilized, this material generally includes layersof a thermoplastic polymer material and a barrier material. Thethermoplastic polymer material provides the ability to form contouredshapes and thermal bonds, as well as a suitable degree of tensilestrength, tear strength, flexural fatigue strength, modulus ofelasticity, and abrasion resistance. The barrier material is effectivein limiting the transmission of the fluid within forefoot component 40(e.g., air, nitrogen, or sulfur-hexafluoride). As another example,forefoot component 40 may be formed from other layered materials,including a flexible microlayer membrane that has alternating layers ofa gas barrier material and an elastomeric material, as disclosed in U.S.Pat. Nos. 6,082,025 and 6,127,026 to Bonk, et al., both of which areincorporated herein by reference. Additional suitable materials aredisclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy, both ofwhich are incorporated herein by reference. Further suitable materialsinclude thermoplastic films containing a crystalline material, asdisclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, andpolyurethane including a polyester polyol, as disclosed in U.S. Pat.Nos. 6,013,340; 6,203,868; and 6,321,465 to Bonk, et al., each of whichare incorporated herein by reference.

The configuration of forefoot component 40 discussed above provides oneexample of a suitable configuration for use in footwear 10 and otherproducts. A variety of other configurations may also be utilized. Forexample, FIG. 10A depicts chambers 43 a-43 f as having D, K, U, O, H,and N-shaped configurations. By varying the shapes of chambers 43 a-43f, the properties of each of chambers 43 a-43 f and different areas offorefoot component 40 may be varied. Referring to FIG. 10B, chambers 43a-43 f are connected across the central area of forefoot component 40,which may decrease longitudinal flexibility in sole structure 30 andprovide additional force attenuation. A similar configuration isdepicted in FIG. 10C, wherein chambers 43 b, 43 c, 43 e, and 43 f arereplaced with various tubes that extend across forefoot component 40.Although flange 44 may be absent or minimal between chambers 43 a-43 f,FIG. 10D depicts a configuration wherein flange 44 extends continuouslyalong opposite sides of forefoot component 40. As a similar example,FIG. 10E depicts chambers 43 a-43 f as being interconnected along theperipheral area of forefoot component 40, also with flange 44 extendingcontinuously along opposite sides of forefoot component 40.

In addition to the configurations discussed above, various other aspectsof forefoot component 40 may vary. Referring to FIG. 11A, chambers 43 cand 43 f are depicted as having greater height, whereas FIG. 11B depictsa lesser height. By varying the heights of chambers 43 a-43 f, thecushioning or force attenuation properties may be modified. Referring toFIG. 11C, a foam element 48 is located between chambers 43 c and 43 fand in contact with web area 45, which may decrease longitudinalflexibility in sole structure 30 and increase cushioning properties.Aspects relating to flange 44 may also vary. Referring to FIG. 11D,flange 44 has a non-tapered and squared configuration, which may addfurther stiffness. In FIG. 11E, the structure flange 44 is substantiallyabsent from forefoot component 40.

Heel Component

Heel component 50 is depicted separate from footwear 10 in FIGS. 12-16and is formed from a polymer material that defines a first or uppersurface 51 and an opposite second or lower surface 52. Whereas uppersurface 51 is secured to upper 20, different portions of lower surface52 are either secured to outsole 60 or exposed and visible from anexterior surface of footwear 10. As with forefoot component 40, uppersurface 51 and lower surface 52 are formed from polymer layers during amolding or thermoforming process. More particularly, upper surface 51 isformed from one polymer layer, and lower surface 52 is formed fromanother polymer layer. Any of the polymer materials noted above forforefoot component 40 may also be utilized for the polymer layersforming heel component 50.

Heel component 50 includes a single chamber 53, a flange 54, and a webarea 55. Chamber 53 and flange 54 each have a generally U-shapedconfiguration that, when incorporated into footwear 10, extends (a)along lateral side 14, (b) around a rear portion of heel region 13, and(c) along medial side 15, thereby extending around a peripheral area ofheel component 50. Like each of chambers 43 a-43 f, chamber 53 enclosesor contains the fluid within heel component 50 and is formed fromseparated or spaced areas of the polymer layers forming surfaces 51 and52. Flange 54 is formed from portions of the polymer layers that aremolded and joined together and protrudes outward from chamber 53. Webarea 55 extends through a central area of heel component 50 and betweenlateral and medial portions of chamber 53. Like flange 54, web area 55is formed from portions of the polymer layers that are joined together.Although adhesive bonding may be utilized in joining the polymer layersin flange 54 and web area 55, thermal bonding may also join the polymerlayers during the molding or thermoforming process.

Chamber 53 is the primary component of heel component 50 that enclosesthe fluid. In areas immediately adjacent to chamber 53, the polymerlayers forming surfaces 51 and 52 are joined to each other to form abond that seals the fluid within heel component 50. More particularly,flange 54 and web area 55 cooperatively bound or otherwise extend aroundchamber 53 and are formed from areas of the polymer layers that arebonded to each other, thereby sealing the fluid within chamber 53. Infurther configurations of footwear 10, chamber 53 may be subdivided intotwo or more subchambers that may be pressurized differently. In otherconfigurations, heel component 50 may be a part of a fluid system thatpumps fluid into chamber 53. In still further configurations, the medialand lateral portions may be connected through a central portion of webarea 55.

Upper surface 51 has a generally concave configuration, as depicted inFIGS. 17A and 17B, that supports the foot when footwear 10 is worn. Assuch, the foot effectively rests within the U-shaped configurations ofchamber 53 and flange 54. This configuration may provide stability tofootwear 10 and ensure that the foot remains properly positionedrelative to heel component 50 and other portions of sole structure 30.

Flange 54 forms a peripheral seam or bonded area that joins the polymerlayers forming surfaces 51 and 52 and assists with sealing the fluidwithin heel component 50. In general, flange 54 has a height of at leastfive millimeters and extends in an outward direction from a remainder ofheel component 50. More particularly, flange 54 extends in an upwarddirection from the peripheral area or an upper area of heel component50. Whereas the area of flange 54 corresponding with first surface 51faces toward and is secured to upper 20, the area of flange 54corresponding with second surface 52 faces away from and forms a portionof an exterior surface of footwear 10. More simply, one surface offlange 54 is secured to upper 20, and the opposite surface of flange 54faces away from upper 20. Given that flange 54 is a relatively thick andstiff portion of heel component 50, flange 54 may enhance the stabilityof footwear 10. As with flange 44, flange 54 may provide a definedlasting margin during steps of the manufacturing process that involvebonding upper 20 to heel component 50.

Referring to the cross-sections of FIGS. 17A and 17B, for example,flange 54 is depicted as having a tapered configuration, with theportions of flange 54 located adjacent to chamber 53 having greaterthickness than the portions of flange 54 that are spaced from chamber53. In effect, therefore, flange 54 has a tapered configuration with afirst thickness adjacent to the void in chamber 53 and a secondthickness spaced away from the void, the first thickness being greaterthan the second thickness. Moreover, the thickness of the portions offlange 54 located adjacent to the void (i.e., the first thickness) isgreater than either of (a) the thickness of web area 45 in the centralarea of heel component 50 and (b) the sum of the thicknesses of thepolymer layers forming surfaces 51 and 52. Although flange 54 is formedfrom the polymer layers forming surfaces 51 and 52 and web area 55,flange 54 has a greater thickness than both of the polymer layerscombined. As noted above, flange 54 is a relatively thick and stiffportion of heel component 50. A portion of the stiffness may be due,therefore, to the greater thickness of flange 54 adjacent to chamber 53.

Web area 55 extends throughout a central area of heel component 50. Inthis position, web area 55 forms a bonded area that joins the polymerlayers forming surfaces 51 and 52 and also assists with sealing thefluid within chamber 53. Whereas chamber 53 protrudes outward to formstructures for receiving the fluid within heel component 50, web area 55exhibits lesser thickness and may provide cushioning or forceattenuation through deflecting downward, similar to a trampoline.

The configuration of heel component 50 discussed above provides oneexample of a suitable configuration for use in footwear 10 and otherproducts. A variety of other configurations may also be utilized. Forexample, flange 54 angles outwardly in FIG. 18A, rather than having avertical orientation. In this configuration, flange 54 may support edgesof the foot, rather than extending along sides of the foot. Referring toFIG. 18B, chamber 53 bulges outward to a lesser degree, which locatesflange 54 at the immediate periphery of heel component 50 and formsvertical sides for heel component 50. As another example, the width ofchamber 53 is increased in FIG. 18C, which may modify the cushioning orforce attenuation properties of heel component 50. In otherconfigurations, flange 54 may have a squared aspect or be absent,similar to FIGS. 11D and 11E.

Although the area between opposite sides of chamber 53 and under webarea 55 may be open, foam elements or other components may be located inthis area. Referring to FIG. 19A, for example, a foam element 56 islocated under and in contact with web area 55. Among other aspects, foamelement 56 may affect the flexibility or force attenuation properties ofheel component 50. Moreover, the shape and location of foam element 56may also affect properties of heel component 50. Referring to FIG. 19B,foam element 56 has a tapered configuration, which may alter propertiesbetween forward and rearward areas of heel component 50. Similarly, foamelement 56 is tapered and spaced from web area 55 in FIG. 19C.Accordingly, heel component 50 may vary in many aspects.

Manufacturing Process for Forefoot Component

Although a variety of manufacturing processes may be utilized to formforefoot component 40, an example of a suitable process will now bediscussed. With reference to FIGS. 20 and 21, a mold 70 that may beutilized in the manufacturing process is depicted as including a firstmold portion 71 and a second mold portion 72. As discussed below inreference to FIGS. 22A-22E, mold 70 is utilized to form forefootcomponent 40 from a first polymer layer 81 and a second polymer layer82, which are the polymer layers respectively forming first surface 41and second surface 42. More particularly, mold 70 facilitates themanufacturing process by (a) shaping polymer layers 81 and 82 in areascorresponding with chambers 43 a-43 f, flange 44, and conduits 46 and(b) joining polymer layers 81 and 82 in areas corresponding with flange44 and web area 45.

Various surfaces or other areas of mold 70 will now be defined for usein discussion of the manufacturing process. Referring to FIGS. 20 and22A, first mold portion 71 includes a pinch surface 73, a firstseam-forming surface 74, and a compression surface 75. Surfaces 73 and74 are angled relative to each other, with pinch surface 73 being morevertical than first seam-forming surface 74. Referring to FIGS. 21 and22A, second mold portion 72 includes a pinch edge 76 and a secondseam-forming surface 77. Whereas pinch edge 76 is a relatively sharpcorner or angled area in second mold portion 72, second seam-formingsurface 77 extends downward and is generally, although not necessarily,parallel to pinch surface 73. A void within mold 70 and between moldportions 71 and 72 has a shape of forefoot component 40, prior topressurization, and forms various features of forefoot component 40. Aportion of this void is identified as a depression 78 in second moldportion 72.

Each of polymer layers 81 and 82 are initially located between each ofmold portions 71 and 72, which are in a spaced or open configuration, asdepicted in FIG. 22A. In this position, first polymer layer 81 ispositioned adjacent or closer to first mold portion 71, and secondpolymer layer 82 is positioned adjacent or closer to second mold portion72. A shuttle frame or other device may be utilized to properly positionpolymer layers 81 and 82. As part of the manufacturing process, one orboth of polymer layers 81 and 82 are heated to a temperature thatfacilitates shaping and bonding. As an example, various radiant heatersor other devices may be utilized to heat polymer layers 81 and 82,possibly prior to being located between mold portions 71 and 72. Asanother example, mold 70 may be heated such that contact between mold 70and polymer layers 81 and 82 at a later portion of the manufacturingprocess raises the temperature to a level that facilitates shaping andbonding.

Once polymer layers 81 and 82 are properly positioned, mold portions 71and 72 translate or otherwise move toward each other and begin to closeupon polymer layers 81 and 82, as depicted in FIG. 22B. As mold portions71 and 72 move toward each other, various techniques may be utilized todraw polymer layers 81 and 82 against surfaces of mold portions 71 and72, thereby beginning the process of shaping polymer layers 81 and 82.For example, air may be partially evacuated from the areas between (a)first mold portion 71 and first polymer layer 81 and (b) second moldportion 72 and second polymer layer 82. More particularly, air may bewithdrawn through various vacuum ports in mold portions 71 and 72. Byremoving air, polymer layers 81 and 82 are drawn into contact with thesurfaces of mold portions 71 and 72. As another example, air may beinjected into the area between polymer layers 81 and 82, therebyelevating the pressure between polymer layers 81 and 82. During apreparatory stage of this process, an injection needle may be locatedbetween polymer layers 81 and 82, and a gas may then be ejected from theinjection needle such that polymer layers 81 and 82 engage the surfacesof mold 70. Each of these techniques may be used together orindependently.

As mold portions 71 and 72 continue to move toward each other, polymerlayers 81 and 82 are pinched between mold portions 71 and 72, asdepicted in FIG. 22C. More particularly, polymer layers 81 and 82 arecompressed between pinch surface 73 and pinch edge 76. In addition tobeginning the process of separating excess portions of polymer layers 81and 82 from portions that form forefoot component 40, the pinching ofpolymer layers 81 and 82 begins the process of bonding or joining layers81 and 82 in the area of flange 44.

Following the pinching of polymer layers 81 and 82, mold portions 71 and72 proceed with moving toward each other and into a closedconfiguration, as depicted in FIG. 22D. In the period between FIGS. 22Cand 22D, pinch surface 73 contacts and slides against a portion ofsecond seam-forming surface 77. The contact between pinch surface 73 andsecond seam-forming surface 77 effectively severs excess portions ofpolymer layers 81 and 82 from portions that form forefoot component 40.In addition, the sliding movement pushes portions of the materialforming polymer layers 81 and 82 downward and further into depression78. Moreover, the material forming polymer layers 81 and 82 compacts orotherwise collects in the area between seam-forming surfaces 74 and 77.Given that seam-forming surfaces 74 and 77 are angled relative to eachother, the compacted polymer material forms a generally triangular ortapered structure, which results in flange 44. In addition to formingflange 44, polymer layers 81 and 82 are (a) shaped to form chambers 43a-43 f and (b) compressed and joined to form web area 45.

At the stage of the process depicted in FIG. 22D, a void within mold 70,which is located between compression surface 75 and depression 78,effectively has the shape of forefoot component 40 prior to inflation orpressurization. Moreover, a peripheral portion of the void includes anarea that forms flange 44 between seam-forming surfaces 74 and 77. Thenon-parallel configuration between seam-forming surfaces 74 and 77results in a tapered space where the polymer material collects to formflange 44. A distance across the space between seam-forming surfaces 74and 77 is greater adjacent to a portion of the void that forms chambers43 a-43 f than in the area where seam-forming surfaces 74 and 77 meet,which is spaced from the portion of the void that forms chambers 43 a-43f. Although the configuration of the tapered space between seam-formingsurfaces 74 and 77 may vary, an angle formed between seam-formingsurfaces 74 and 77 may be in a range of twenty and forty-five degrees.

As discussed above, the material forming polymer layers 81 and 82compacts or otherwise collects in the area between seam-forming surfaces74 and 77. This compaction effectively thickens one or both of polymerlayers 81 and 82. That is, whereas polymer layers 81 and 82 have a firstthickness at the stage depicted in FIG. 22A, one or both of polymerlayers 81 and 82 within flange 44 may have a second, greater thicknessat the stage depicted in FIG. 22D. The compaction that occurs as pinchsurface 73 contacts and slides against a portion of second seam-formingsurface 77 increases the thickness of the polymer material forming oneor both of polymer layers 81 and 82.

When forming forefoot component 40 is complete, mold 70 is opened andforefoot component 40 is removed and permitted to cool, as depicted inFIG. 22E. A fluid may then be injected into forefoot component 40 topressurize chambers 43 a-43 f, thereby completing the manufacture offorefoot component 40. As a final step in the process, forefootcomponent 40 may be incorporated into sole structure 30 of footwear 10.

Manufacturing Process for Heel Component

Although a variety of manufacturing processes may be utilized, heelcomponent 50 may be formed through a process that is generally similarto the process discussed above for forefoot component 40. With referenceto FIGS. 23 and 24, a mold 90 that may be utilized in the manufacturingprocess is depicted as including a first mold portion 91 and a secondmold portion 92. As discussed below in reference to FIGS. 25A-25D, mold90 is utilized to form heel component 50 from additional elements offirst polymer layer 81 and second polymer layer 82, which are thepolymer layers respectively forming first surface 51 and second surface52. More particularly, mold 90 facilitates the manufacturing process by(a) shaping polymer layers 81 and 82 in areas corresponding with chamber53 and flange 54 and (b) joining polymer layers 81 and 82 in areascorresponding with flange 54 and web area 55. In addition, mold 90facilitates the bonding of outsole 60 to heel component 50.

Each of polymer layers 81 and 82 are initially located between each ofmold portions 91 and 92, as depicted in FIG. 25A. In addition, one ormore elements that form outsole 60 are also located relative to mold 90.Once polymer layers 81 and 82 are properly positioned and the elementsof outsole 60 are located within depressions in second mold portion 91,mold portions 91 and 92 translate or otherwise move toward each otherand begin to close upon polymer layers 81 and 82, as depicted in FIG.25B. As discussed above, air may be partially evacuated from the areasbetween (a) first mold portion 91 and first polymer layer 81 and (b)second mold portion 92 and second polymer layer 82. Additionally, airmay be injected into the area between polymer layers 81 and 82. Usingone or both of these techniques, polymer layers 81 and 82 are induced toengage the surfaces of mold 90. Additionally, polymer layers 81 and 82also lay against outsole 60. In effect, therefore, polymer layers 81 and82 are shaped against surfaces of mold 90 and outsole 60.

As mold portions 91 and 92 continue to move toward each other, polymerlayers 81 and 82 are compressed between mold portions 91 and 92, asdepicted in FIG. 25C. More particularly, polymer layers 81 and 82 arecompressed to form flange 54 and web area 55. Polymer layer 82 alsobonds with outsole 60. In some configurations, outsole 60 may be thermalbonded to heel component 50 during the manufacturing process. Forexample, when each of polymer layer 82 and outsole 60 are formed fromsimilar or compatible polymer materials, or when outsole 60 is at leastpartially formed from the polymer material of chamber 53, heating of thecomponents may induce thermal bonding between the components.

When forming heel component 50 is complete, mold 90 is opened and heelcomponent 50 is removed and permitted to cool, as depicted in FIG. 25D.A fluid may then be injected into heel component 50 to pressurizechamber 53, thereby completing the manufacture of heel component 50. Asa final step in the process, heel component 50 may be incorporated intosole structure 30 of footwear 10.

As polymer layers 81 and 82 are drawn into mold 90, particularly thelarger depressions in second mold portion 91, polymer layers 81 and 82stretch to conform with the contours of mold 90. When polymer layers 81and 82 stretch, they also thin or otherwise decrease in thickness.Accordingly, the initial thicknesses of polymer layers 81 and 82 may begreater than the resulting thicknesses after the manufacturing process.

Referring to FIGS. 26A and 26B, various thickness dimensions 83, 84, and85 are defined. Thickness dimension 83 is measured in an upper area ofchamber 53 and between an exterior surface of chamber 53 and an interiorsurface of chamber 53, which defines the void. Thickness dimension 84 ismeasured in a lower area of chamber 53 and between the exterior andinterior surfaces of chamber 53. Thickness dimension 85 is measured inthe same place as thickness dimension 84 and between an outer surface ofoutsole 60 and the interior surface of chamber 53.

For footwear applications, as noted above, a polymer thickness of 0.75millimeter (0.03 inch) and a fluid pressure of 138 kilopascals (20pounds per square inch) provides a suitable degree of compliance, forceattenuation, and other properties. Polymer thicknesses of less than 0.75millimeter may rupture or otherwise fail prematurely or after repeateduse. The manufacturing processes for many chambers are designed,therefore, to ensure that the polymer thickness remains at or above 0.75millimeter. In the manufacturing process for heel component 50, however,the relatively deep depressions in second mold portion 92 may result inthinning of second polymer layer 82 that is below the 0.75 millimeterthreshold. That is, second polymer layer 82 may thin to a degree thatmakes heel component susceptible to rupturing. The bonding of outsole 60to heel component 50, however, effectively thickens and reinforces thelower area of heel component 50.

Given the above discussion, thickness dimension 83 may be approximately0.75 millimeter and thickness dimension 84 may be less than 0.75millimeter, and possibly less than 0.50 millimeter (0.02 inch) or morethan fifty percent less than thickness dimension 83. The addition ofoutsole 60 increases the thickness in the lower area of heel component50, and generally increases the thickness to more than 0.75 millimeter.As such, thickness dimension 83 may be (a) more than thickness dimension84 and (b) less than thickness dimension 85. Moreover, designing heelcomponent 50 such that thickness dimension 85 is greater than thicknessdimension 83 ensures that outsole 60 may wear from contact with theground.

In addition to providing a wear surface in footwear 10, outsole 60 mayenhance various properties of sole structure 30. The thickness,flexibility, and stretch of outsole 60, for example, may be varied orselected to modify or otherwise tune the cushioning response,flexibility, compressibility, and other properties of sole structure 30.Ribs, apertures, or other features of outsole 60 may also affect theresulting properties of sole structure 30. Outsole 60 may alsoincorporate tread elements (e.g., protrusions, ridges) that impartstraction. Regarding aesthetics, outsole 60 may be colored, clear, orpatterned to enhance the visual appeal of footwear 100. In someconfigurations, outsole 60 may be replaced by a plate or otherstructural element in the manufacturing process discussed above. Inaddition to modifying the properties of sole structure 30, a plate mayhave features that assist with securing an outsole or other element toheel component 50.

FIG. 27 shows another configuration of an article of footwear 110.Features of the article of footwear 110 that are the same as those shownand described with respect to article of footwear 10 are indicated withlike reference numbers. The article of footwear 110 has a sole structure130 that includes a cushioning component 132 defining an enclosed,fluid-filled chamber 143. As best shown in FIG. 29, the sole structure130 also includes a unitary outsole 160 bonded to a bottom wall 124 andto side walls 126, 128 of the cushioning component 132 such that theoutsole 160 wraps substantially up the side walls 124, 126. The outsole160 is also bonded to a rear wall 127 and a front wall 129 of thecushioning component 132, as indicated in FIG. 27. As shown in FIGS.27-31, the outsole 160 includes integral tread portions 161 that can beinjection molded integrally with a body portion 170 of the unitaryoutsole 160. Alternatively, the tread portions 161 can be positioned ina mold assembly adjacent the body portion 170 and can thermally bond tothe body portion 170 during molding of the cushioning component 132. Thetread portions 161 may have a variety of different shapes and patterns.

The cushioning component 132 may be formed from a polymer material, suchas any of the polymer materials described with respect to the article offootwear 10. For example, in the embodiment of FIG. 27, the cushioningcomponent 132 includes a first polymer sheet 181 and a second polymersheet 182, which may also be referred to as an upper polymer sheet and alower polymer sheet, respectively. The second polymer sheet 182 isbonded to the first polymer sheet 181 so that the first and secondpolymer sheets form a peripheral flange 144 and define the fluid-filledchamber 143. More specifically, with reference to FIG. 29, the firstpolymer sheet 181 forms a top wall 122 of the cushioning component 132.The second polymer sheet 182 forms a bottom wall 124, a medial side wall126 and a lateral side wall 128 of the cushioning component 132.

The first and second polymer sheets 181, 182 may be molded bythermoforming, as described herein, so that the peripheral flange 144 isnearer the top wall 122 than the bottom wall 124 as shown in FIG. 29.This allows the flange 144 of the cushioning component 132 to bond toand cup the upper 120 by extending along lateral and medial surfaces134, 136 of the upper 120 as shown in FIGS. 27-30 and as furtherdiscussed herein. In the embodiment shown, the cushioning component 132includes a forefoot portion 184, a midfoot portion 186, and a heelportion 188 corresponding with the forefoot portion 11, the midfootportion 12, and the heel portion 13 of the article of footwear 110, andthe chamber 143 formed by the cushioning component 132 extends under theupper 120 at the forefoot portion 11, the midfoot portion 12, and theheel portion 13 of the article of footwear 110. The cushioning component132 may thus be referred to as a full length cushioning component.

In one embodiment, the first and second polymer sheets 181, 182 aremulti-layer polymer sheets including thermoplastic polyurethane layersalternating with barrier layers that comprise a copolymer of ethyleneand vinyl alcohol (EVOH) impermeable to fluid contained in the chamber143. The fluid may be air, nitrogen, or another gas used to inflate thechamber 143.

As best shown in FIGS. 29 and 30, the cushioning component 132 mayinclude a tether element 162 within the chamber 143. The tether element162 includes a first plate 163 bonded to an inner surface 164 of the topwall 122. The tether element 162 further includes a second plate 165bonded to an inner surface 166 of the bottom wall 124. The plates 163,165 may be a thermoplastic material that thermally bonds to the firstand second polymer sheets 181, 182 during thermoforming of the polymersheets 181, 182, as discussed with respect to FIG. 32. As shown in FIG.27 the plates 163, 165 extend through the entire cushioning component132, in the forefoot portion 184, the midfoot portion 186, and the heelportion 188. In other embodiments, the plates 163, 165 may extend inonly one or only two of the forefoot portion 184, the midfoot portion186, and the heel portion 188, or multiple tether elements can besecured to the first and second polymer sheets 181, 182 within thechamber 143.

The cushioning component 132 also includes a plurality of tethers 168secured to the first plate 163 and to the second plate 165 and extendingin the fluid-filled chamber 143 between the first plate 163 and thesecond plate 165. The tethers 168 are placed in tension by fluid in thechamber 143, and, because they are secured to the plates 163, 165, actto control the shape of the cushioning component 132 when the chamber143 is filled with pressurized fluid. The tethers 168 may be any of avariety of different configurations including single strands of textiletensile members secured at each end to plates 163, 165, or repeatedlypassing through one or both plates 163, 165. Various configurations oftethers are shown and described in U.S. Pat. No. 8,479,412, which ishereby incorporated by reference in its entirety.

Multiple rows of tethers 168 are present and extend across a width ofthe plates 163, 165 between the lateral side 14 and the medial side 15of the article of footwear 110. FIG. 27 shows multiple rows of tethers168 extending laterally and positioned in the forefoot region 11, themidfoot region 12, and the heel region 13. Each tether 168 shown in thecross-section of FIG. 29 is in one row, and each tether 168 shown in thecross-section of FIG. 29 is in a different row than the row shown inFIG. 29.

The outsole 160 has a bottom portion 142, a medial side portion 145, anda lateral side portion 146. As shown in FIG. 27, the bottom portion 142is bonded to an outer surface 147 of the second polymer sheet 182 at thebottom wall 124 of the cushioning component 132. The bottom portion 142of the outsole 160 is coextensive with the bottom wall 124 of thecushioning component 132. The medial side portion 145 of the outsole 160is bonded to the outer surface 147 of the second polymer sheet 182 atthe medial side wall 126 of the cushioning component 132, and thelateral side portion 146 of the outsole 160 is bonded to the outersurface 147 of the second polymer sheet 182 at the lateral side wall 128of the cushioning component 132.

One or both of the side portions 145, 146 of the outsole 160 may includeone or more peaks and one or more valleys. For example, at least one ofthe lateral side portion 146 and the medial side portion 145 may form atleast one peak disposed between the midfoot portion 186 and the heelportion 188, and at least one valley disposed rearward of the at leastone peak. In the embodiment shown, the peaks may be referred to asspaced fingers and the valleys may be referred to as notches defined bythe spaced fingers. In particular, a peak that has a height greater thanits width may be referred to as a finger, and a valley that has a depthgreater than its width may be referred to as a notch. For example, withreference to FIG. 27, the lateral side portion 146 includes a pluralityof spaced peaks 148A, 148B, 148C, 148D, 148E, 148F, 148G, 148H, 148I andvalleys 150A, 150B, 150C, 150D, 150E, 150F, 150G, 150H, 150I betweenadjacent ones of the peaks 148A, 148B, 148C, 148D, 148E, 148F, 148G,148H, 148I. Similarly, FIG. 28 shows that the medial side portion 145 ofthe outsole 160 includes a plurality of spaced peaks 148J, 148K, 148L,148M, 148N, 148O, 148P, 148Q, 148R, 148S, 148T, and 148U and valleys150J, 150K, 150L, 150M, 150N, 150O, 150P, 150Q, 150R, and 150S betweenadjacent ones of the peaks 148J, 148K, 148L, 148M, 148N, 148O, 148P,148Q, 148R, 148S, 148T, and 148U. Additional peaks and valleys may beincluded between peaks 148O and 148P at a portion of the outsole 160covered by the upper 120 in the view of FIG. 28.

FIGS. 27 and 28 show that the peaks 148A, 148B, 148C, 148D, 148E, 148F,148G, 148H, 148I, 148J, 148K, 148L, 148M, 148N, 148O, 148P, 148Q, 148R,148S, 148T, and 148U are at least partially aligned with the tetherelement 162. The peaks 148A, 148B, 148C, 148D, 148E, 148F, 148G, 148H,148I, 148J, 148K, 148L, 148M, 148N, 148O, 148P, 148Q, 148R, 148S, 148T,and 148U are positioned along the forefoot portion 184, the midfootportion 186 and the heel portion 188 of the cushioning component 132,and the tether element 162 extends in each of these portions. At leastsome of the peaks 148A, 148B, 148C, 148D, 148E, 148F, 148G, 148H, 148I,148J, 148K, 148L, 148M, 148N, 148O, 148P, 148Q, 148R, 148S, 148T, and148U are also aligned with one or more rows of the tethers 168. A peakis aligned with a row of tethers 168 when it is positioned laterallyadjacent the row. For example, FIG. 27 shows peak 148D laterally alignedwith two different rows R1, R2 of the tethers 168. The valleys 150C,150D, on the other hand, may be aligned with spaces between the rows oftethers 168. The positioning of the peaks and the valleys relative tothe rows of tethers 168 can provide support to and flexibility of thecushioning component 132, respectively. There may be fewer or more peaksand valleys than shown in the embodiment of FIGS. 27 and 28, and thepeaks and valleys may have different shapes than shown. For example, thepeaks may be wider than shown, each extending further forward andrearward along the medial or lateral side portion 145 or 146. In someembodiments, there may be only one peak. The single peak may bepositioned at or rearward of the midfoot portion 186, and a valley maybe rearward of the single peak.

The spaced peaks 148A, 148B, 148C, 148D, 148E, 148F, 148G, 148H, 148I,148J, 148K, 148L, 148M, 148N, 148O, 148P, 148Q, 148R, 148S, 148T, and148U are configured to vary in height. In the embodiment shown in FIG.27, a first one of the peaks 148B is at the heel portion 188 and has afirst height H1. The height of each peak may be measured from a baselineat a lowest extend of an adjacent valley, to an upper edge of the peak148B. For example, as shown in FIG. 27, the height H1 of peak 148B isfrom the baseline 152 at the lowest extent of valley 150A to the upperedge 154. A second one of the peaks 148H is at the forefoot portion 184and has a second height H2 less than the first height H1. Generally,peaks in the heel portion 188 have a greater height than peaks in theforefoot portion. The peaks in the midfoot portion 186 have heights lessthan the heights of the peaks in the heel portion. Optionally, the peaksin the midfoot portion 186 can have a height less than the height of thepeaks in the forefoot portion 184. For example, a third one of the peaks148E is at the midfoot portion 186 and has a third height H3 less thanthe second height H2.

In the embodiment of FIGS. 27-30 the entire outsole 160 is substantiallytransparent, and may be a substantially transparent thermoplasticpolyurethane material. The polymer sheets 181, 182 can also besubstantially transparent. This allows the tethers 168 to be viewedthrough the outsole 160 and the second sheet 182. The tethers 168 can beviewed through both the peaks and the valleys. Those skilled in the artwill readily understand a variety of methods to determine transparencyof an object, such as by a test of luminous transmittance and haze. Forexample, the luminous transmittance and haze of the cushioning component132 and of the outsole 160 can be determined according to AmericanSociety for Testing and Materials (ASTM) Standard D1003-00, StandardTest Method for Haze and Luminous Transmittance of Transparent Plastics.

FIG. 31 shows an alternative embodiment of an article of footwear 110Aalike in all aspects to the article of footwear 110, except that anoutsole 160A is used that is not substantially transparent. For example,the outsole 160A can be an opaque material, such as a durable rubbermaterial. In such an embodiment, the tethers 168 can be viewed throughthe second sheet 182 at the valleys of the outsole 160A, but not throughthe peaks of the outsole 160A, as illustrated with respect to peaks148A-148I and valleys 150A-150I.

With reference to FIG. 29, the cushioning component 132 is secured tothe upper 120 so that a bottom surface 190 of the upper 120 is securedto and supported on the top wall 122 of the cushioning component 132,and the peripheral flange 144 is bonded to the lateral surface 134 andthe medial surface 136 of the upper 120. In an embodiment in which anadditional footwear component, such as additional midsole layer, ispositioned between the cushioning component 132 and the upper 120, theflange 144 could bond to and cup the additional footwear component inaddition to or instead of the upper 120, depending upon how far upwardthe flange 144 extends.

FIG. 32 shows a mold assembly 70A that can be used to manufacture thecushioning component 132. Features of the mold assembly 70A that are thesame as those described with respect to mold 70 are indicated with likereference numbers. The mold assembly 70A is substantially identical tothe mold 70 of FIG. 22A except that a second mold portion 72A is usedthat has an inner surface 79 shaped with relatively deep side grooves ordepressions 87, also referred to as accumulator portions, and ashallower central depression 78A. The outsole 160 is preformed in theshape shown in FIG. 32 that generally corresponds to the inner surface79, with protrusions 93 at the intersection of the bottom portion 142and the side portions 145, 146. The preformed shape of the outsole 160with the protrusions 93 and the inner surface 79 of the mold portion 72Ashown in FIG. 32 enables the plates 163, 165 to be compressed againstand thermally bond to the first and second polymer sheets 181, 182 whenthe mold assembly 70A is closed, at the same time that the sheets 181,182 are compressed and thermally bond to one another at the flange 144.After thermoforming, upon inflation of the fluid-filled chamber 43, theinternal pressure causes the protrusions 93 to generally flatten outrelative to the bottom portion 142, as shown in FIG. 29.

A method of manufacturing the article of footwear 110 or 110A using themold 70A includes disposing first and second polymer sheets 181, 182 ina mold assembly 70A, and disposing a preformed unitary outsole, such asoutsole 160 or 160A in the mold assembly 70A adjacent the second polymersheet 182. The method may also include disposing the tether element 162in the mold assembly 70A between the first and second polymer sheets181, 182. The tether element 162 can be formed and inflated prior toplacement in the mold assembly 70A, placing the tethers 168 in tension.The outsole 160 or 160A is disposed so that the second polymer sheet 182is between the tether element 162 and the outsole 160 or 160A. Theoutsole 160 or 160A may be preformed by injection molding or otherwiseprior to placement in the mold assembly 70A. Disposing the preformedunitary outsole 160 adjacent the second polymer sheet 182 may includealigning the peaks 148A, 148B, 148C, 148D, 148E, 148F, 148G, 148H, 148I,148J, 148K, 148L, 148M, 148N, 148O, 148P, 148Q, 148R, 148S, 148T, and148U with the tether element 162, such as with the rows of tethers 168,as discussed with respect to FIG. 27.

The first and second polymer sheets 181 and 182 may be preheated priorto placement in the mold assembly 70A to aid in formability of thesheets to the mold surfaces. The mold assembly 70A is closed. Heat andpressure are applied to thermoform the sheet 181 to the surface of themold portion 71. Vacuum forming may be used to draw the sheet 181against the mold portion 71, and to draw the sheet 182 against theoutsole 160, and against the portions of the surface of the mold portion72A where the flange 144 is formed.

The components within the mold assembly 70A thermally bond to oneanother during the thermoforming process. More specifically, the firstand second polymer sheets 181, 182 thermally bond to one another at theflange 144 to form the cushioning component 132 with the chamber 143containing the tether element 162. The tether element 162 thermallybonds to inner surfaces 164, 166 of the first and second polymer sheets181, 182, respectively. The first plate 163 thermally bonds to the topwall 122 of the first polymer sheet 181, and the second plate 165thermally bonds to the bottom wall 124 of the second polymer sheet 182.Additionally, the bottom portion 170 of the outsole 160 thermally bondsto the outer surface 147 of the bottom wall 124 of the second polymersheet 182. The medial side portion 145 of the outsole 160 thermallybonds to the medial side wall 126 of the second polymer sheet 182. Thelateral side portion 146 of the outsole 160 thermally bonds to thelateral side wall 128 of the second polymer sheet 182.

After the cushioning component 132 is formed with the outsole 160thermally bonded thereto, the cushioning component 132 is removed fromthe mold assembly 70A, and the peripheral flange 144 is secured to theside surfaces 134, 136 of an additional footwear component, such as theupper 120. The peripheral flange 144 is also secured to the surface ofthe upper 120 at the rear of the heel portion 13 and at the front of theforefoot portion 11 as is evident in FIG. 27. The flange 144 thus cupsthe entire periphery of the upper 120 and the first polymer sheet 181extends across the entire bottom surface 190 of the upper 120. An insole192 can be secured in the upper 120.

An article of footwear 2100 is depicted in FIG. 33 and FIG. 34 asincluding an upper 2120 and a sole structure 2130. Upper 2120 provides acomfortable and secure covering for a foot of a wearer. As such, thefoot may be located within upper 2120 to effectively secure the footwithin article of footwear 2100 or otherwise unite the foot and articleof footwear 2100. Sole structure 2130 is secured to a lower area ofupper 2120 and extends between the foot and the ground to attenuateground reaction forces (i.e., cushion the foot), provide traction,enhance stability, and influence the motions of the foot, for example.In effect, sole structure 2130 is located under the foot and supportsthe foot.

For reference purposes, footwear 2100 may be divided into three generalregions: a forefoot region 2111, a midfoot region 2112, and a heelregion 2113. Forefoot region 2111 generally includes portions of articleof footwear 2100 corresponding with toes of the foot and the jointsconnecting the metatarsals with the phalanges. Midfoot region 2112generally includes portions of footwear 2100 corresponding with an archarea of the foot. Heel region 2113 generally corresponds with rearportions of the foot, including the calcaneus bone. Article of footwear2100 also includes a lateral side 2114 and a medial side 2115, whichcorrespond with opposite sides of article of footwear 2100 and extendthrough each of forefoot region 2111, midfoot region 2112, and heelregion 2113. More particularly, lateral side 2114 corresponds with anoutside area of the foot (i.e. the surface that faces away from theother foot), and medial side 2115 corresponds with an inside area of thefoot (i.e., the surface that faces toward the other foot). Forefootregions 2111, midfoot region 2112, heel region 2113, lateral side 2114,and medial side 2115 are not intended to demarcate precise areas offootwear 2100. Rather, forefoot region 2111, midfoot region 2112, heelregion 2113, lateral side 2114, and medial side 2115 are intended torepresent general areas of footwear 2100 to aid in the followingdiscussion. The characterizations of forefoot region 2111, midfootregion 2112, heel region 2113, lateral side 2114, and medial side 2115may be applied to article of footwear 2100, and also may be applied toupper 2120, sole structure 2130, forefoot structure 2131, heel structure2132, and individual elements thereof.

Upper 2120 is depicted as having a substantially conventionalconfiguration. A majority of upper 2120 incorporates various materialelements (e.g., textiles, foam, leather, and synthetic leather) that arestitched or adhesively bonded together to form an interior void forsecurely and comfortably receiving a foot. The material elements may beselected and located in upper 2120 to selectively impart properties ofdurability, air-permeability, wear-resistance, flexibility, and comfort,for example. The void in upper 2120 is shaped to accommodate the foot.When the foot is located within the void, upper 2120 extends along alateral side of the foot, along a medial side of the foot, over thefoot, around the heel, and under the foot. An ankle opening 2121 in heelregion 2113 provides the foot with access to the void. A lace 2122extends over a tongue 2123 and through various lace apertures 2124 orother lace-receiving elements in upper 2120. Lace 2122 and theadjustability provided by tongue 2123 may be utilized in a conventionalmanner to modify the dimensions of ankle opening 2121 and the interiorvoid, thereby securing the foot within the interior void andfacilitating entry and removal of the foot from the interior void.

Further configurations of upper 2120 may also include one or more of (a)a toe guard positioned in forefoot region 2111 and formed of awear-resistant material, (b) a heel counter located in heel region 2113for enhancing stability, and (c) logos, trademarks, and placards withcare instructions and material information. Given that various aspectsof the present discussion primarily relate to sole structure 2130, upper2120 may exhibit the general configuration discussed above or thegeneral configuration of practically any other conventional ornon-conventional upper. Accordingly, the structure of upper 2120 mayvary significantly within the scope of the present disclosure.

Sole Structure

The primary elements of sole structure 2130 are a forefoot solestructure 2131 including a forefoot component 2140 and a forefootoutsole 2160, and a heel sole structure including a heel component 2150and a heel outsole 2170. In some embodiments, each of forefoot component2140 and heel component 2150 may be directly secured to a lower area ofupper 2120. Forefoot component 2140 and heel component 2150 may bereferred to herein as barriers, and are formed from a polymer materialthat encloses a fluid, which may be a gas, liquid, or gel. Duringwalking and running, for example, forefoot component 2140 and heelcomponent 2150 may compress between the foot and the ground, therebyattenuating ground reaction forces. That is, forefoot component 2140 andheel component 2150 are inflated and generally pressurized with thefluid to cushion the foot.

In some configurations, sole structure 2130 may include a foam layer,for example, that extends between upper 2120 and one or both of forefootcomponent 2140 and heel component 2150, or a foam element may be locatedwithin indentations in the lower areas of forefoot component 2140 andheel component 2150. In other configurations, forefoot sole structure2131 may incorporate plates, moderators, lasting elements, or motioncontrol members that further attenuate forces, enhance stability, orinfluence the motions of the foot. Heel sole structure 2132 also mayinclude such members to further attenuate forces, enhance stability, orinfluence the motions of the foot.

In addition to providing a wear surface in article of footwear 2100,forefoot outsole 2160 and heel outsole 2170 may enhance variousproperties and characteristics of sole structure 2130. Properties andcharacteristics of the outsoles, such as the thickness, flexibility, theproperties and characteristics of the material used to make the outsole,and stretch, may be varied or selected to modify or otherwise tune thecushioning response, compressibility, flexibility, and other propertiesand characteristics of sole structure 2130. Reinforcement of the outsole(for example, inclusion of structural elements, such as ribs),apertures, the height of the overlap, the number and location of theedges that overlap, or other features of an outsole all may be used totune the responses of the sole structure. An outsole also mayincorporate tread elements, such as protrusions, ridges, orground-engaging lugs or sections, that impart traction. In someembodiments, an outsole may be replaced by a plate or other structuralelement. A plate may have features that assist with securing an outsoleor other element to heel component 2150.

In particular, overlap of a portion of an outsole away from theground-engaging portion and up the edge of a forefoot component or aheel component may be used to tune the elastic response and cushioningresponse of the resultant sole structure. An edge of a forefootcomponent or a heel component may also be referred to herein as asidewall, side wall, or wall. With the guidance provided herein, theseand other properties and characteristics of the outsole may beconsidered by the user in combination with the properties andcharacteristics of the fluid-filled components of the components toadjust the responses of a sole structure.

Sole structure 2130 may be translucent or transparent, and may becolored or patterned for aesthetic appeal.

Forefoot outsole 2160 is secured to lower areas of forefoot component2140. In some embodiments, forefoot sole structure 2131 may extend intomidfoot region 2112. The forefoot outsole 2160 also may be secured tolower areas of forefoot component 2140 in midfoot region 2112. Heeloutsole 2170 is secured to lower areas of heel component 2150. Both heelcomponent 2150 and heel outsole 2170 may extend into midfoot region2112. Forefoot outsole 2160 and heel outsole 2170 may be formed from awear-resistant material. The wear-resistant material may be transparentor translucent to provide a visually appealing effect. Thewear-resistant material may be textured on the ground-engaging portionsto impart traction. In some embodiments, the wear-resistant material mayhave ground-engaging lugs or portions 2135, as illustrated in FIG. 33and FIG. 34.

FIG. 35 illustrates a cross-sectional view of article of footwear 2100at section line 35-35 of FIG. 33 with forefoot sole structure 2131,including forefoot component 2140 and forefoot outsole 2160 withground-engaging lugs 2135. As depicted in FIG. 35, upper 2120 alsoincludes a sock-liner 2125 that is located within the void andpositioned to extend under a lower surface of the foot to enhance thecomfort of article of footwear 2100.

FIG. 36 illustrates a bottom view of another embodiment of forefoot solestructure 3131 including forefoot component 3140 and forefoot outsole3160 with ground-engaging lugs 3135 associated therewith. Forefootcomponent 3140 can be directly secured to a lower area of upper 2120 ofFIG. 35 and is formed from a polymer material that encloses a fluid,which may be a gas, liquid, or gel. Forefoot component 3140 may extendinto midfoot region 2112. Forefoot component 3140 may compress betweenthe foot and the ground, thereby attenuating ground reaction forces.Fluid-filled chambers 3145 of forefoot component 3140 may be inflatedand generally pressurized with a fluid to cushion the foot.

Forefoot outsole 3160, which also may extend into midfoot region 2112,is secured to lower areas of forefoot component 3140. Forefoot outsole3160 may include individual portions that cover individual lower areasof fluid-filled chambers 3145 of forefoot component 3140. Forefootoutsole 3160 may be formed from wear-resistant material and, in comeembodiments, may include ground-engaging portions or lugs 3135. Forefootoutsole 3160 may be transparent or translucent, and, in someembodiments, may be textured to improve traction.

Forefoot component 2140 and heel component 2150 are formed from apolymer material that defines an upper surface, a lower surface, and anedge. Forefoot component 2140 may include a plurality of forefootcomponent fluid-filled chambers 2145 and heel component 2150 may includea plurality of fluid-filled chambers 2155, each of which may be in fluidcommunication with at least one other chamber of the component. Uppersurface 2141 of forefoot component 2140 is facing downward so that theforefoot component lower surface 2142 and forefoot component edge 2143of each forefoot component fluid-filled chamber 2145 are clearly visiblein FIG. 38. Similarly, upper surface 3141 of forefoot component 3140 isfacing downward so that the forefoot component lower surface 3142 andforefoot component edge 3143 of each forefoot component fluid-filledchamber 3145 are clearly visible in FIG. 40. Heel component fluid-filled chamber 2155, heel component upper surface 151, heel componentlower surface 2152, and heel component edge 2153 of heel component 2150are illustrated in FIG. 39.

FIG. 37 illustrates an exemplary bottom surface of forefoot outsole2160. Forefoot outsole 2160 includes forefoot outsole compartments 2165having ground-engaging lugs 2135 on forefoot outsole outer lower surface2162. Forefoot outsole compartments 2165 also include forefoot outsoleoutside edge 2163.

The relationship between an embodiment of forefoot component 2140 and anembodiment of forefoot outsole 2160 is illustrated in FIG. 38. In thisembodiment, each forefoot component fluid-filled chamber 2145corresponds with a similarly-sized, congruently-shaped forefoot outsolecompartment 2165. In this embodiment, each forefoot outsole compartment2165 is aligned with and sufficiently large to accommodate asimilarly-sized, congruently-shaped forefoot component fluid-filledchamber 2145. In some embodiments, a forefoot component fluid-filledchamber 2145 may combine with a forefoot outsole compartment 2165 in asnug relationship. Forefoot outsole 2160 then may be associated withforefoot component 2140 by inserting forefoot component fluid-filledchambers 2145 into the corresponding forefoot outsole compartments 2165.In some embodiments, a forefoot outsole compartment 2165 is bonded to aforefoot component fluid-filled chamber 2145. In some embodiments,forefoot component 2140 is co-molded with forefoot outsole 2160. In someembodiments, forefoot outsole 2160 is co-extensive with or overlaps atleast a part of forefoot component lower surface 2142 or of insidesurface 2164. In some embodiments, forefoot component edge 3143 isco-extensive with or overlaps at least a part of forefoot componentlower surface 3142 or sole inside surface 3164. In some embodiments,forefoot outsole compartments 2165 surround forefoot componentfluid-filled chambers 2145.

FIG. 39 depicts a relationship between an embodiment of heel component2150 and an embodiment of heel outsole 2170. In this embodiment, a heelcomponent fluid-filled chamber 2155 corresponds with a heel outsolecompartment 2175. In the embodiment illustrated in FIG. 39, the singleheel outsole compartment 2175 may be associated with a similarly-sized,congruently-shaped heel component fluid-filled chamber 2155. In anotherembodiment, heel component 2150 may comprise plural fluid-filledchambers 2155 and heel outsole 2170 may comprise plural heel outsolecompartments 2175. In these embodiments, each heel outsole 2170 fitsonto similarly-sized, congruently-shaped heel component 2150 by ensuringthat each heel outsole compartment 2175 is aligned with and sufficientlylarge enough to accommodate each heel component fluid-filled chamber2155. In some embodiments, a heel component fluid-filled chamber 2155may combine with a heel outsole compartment 2175 in a snug relationship.Heel outsole 2170 then may be associated with heel component 2150 byinserting heel component fluid-filled chambers 2155 into thecorresponding heel outsole compartments 2175. In some embodiments, aheel outsole compartment 2175 is bonded to a heel component fluid-filledchamber 2155. In some embodiments, heel component 2150 is co-molded withheel outsole 2170. In some embodiments, heel outsole compartment 2175surrounds heel component fluid-filled chamber 2155. In some embodiments,the heel outsole 2170 is co-extensive with or at least partly overlapsat least a part of heel component edge 2153.

FIG. 40 illustrates a relationship between forefoot component 3140 andforefoot outsole 3160 in forefoot sole structure 3131. Each of forefootcomponent fluid-filled chambers 3145 has a section or compartment offorefoot outsole 3160 associated therewith. Each forefoot outsolesection of forefoot outsole 3160 may wrap around the corner betweenforefoot component fluid-filled chamber lower surface 3142 and forefootcomponent fluid-filled chamber edge 3143 of one of the forefootcomponent fluid-filled chambers 3145 of forefoot component 3140. Lugs3135 may be attached to or formed on the lower surface of forefootoutsole 3160.

Forefoot sole structure 3131 includes forefoot component 3140 havingforefoot component fluid-filled chambers 3145 formed from a polymermaterial that defines forefoot component upper surface 3141, forefootcomponent lower surface 3142, and forefoot component edge 3143. Forefootcomponent upper surface 3141 is facing downward in FIG. 40.

FIG. 40 also illustrates the relationship between an embodiment offorefoot outsole 3160 and forefoot component 3140. As illustrated inFIG. 40, forefoot outsole 3160 includes forefoot outsole outer lowersurface 3162 having ground-engaging lugs 3135 thereon. Forefoot outsole3160 further includes forefoot outsole compartment edges 3163 thatextend over at least part of forefoot component edge 3143.

Method for Manufacture

An outsole may be attached to a corresponding component in any suitablemanner. In some embodiments, the outsole and component are adhered byadhesion as part of a co-molding process. In some embodiments, theoutsole and corresponding component are adhered by partial melting aspart of a co-molding process.

Forefoot component 2140 and heel component 2150 may be formed from anysuitable polymeric material. Forefoot component 2140 and heel component2150 may be formed of a single layer of material or multiple layers, andmay be thermoformed or otherwise shaped. Examples of polymeric materialsthat may be utilized for forefoot component or a heel component includeany of polyurethane, urethane, polyester, polyester polyurethane,polyether, polyether polyurethane, latex, polycaprolactone,polyoxypropylene, polycarbonate macroglycol, and blends thereof. Theseand other polymeric materials, and an exemplary embodiment of forefootcomponent and heel component, and of a method for manufacturing them,may be found in co-pending application Ser. No. 13/773,360, filed Feb.21, 2013, by Campos II et al., and entitled ARTICLE OF FOOTWEARINCORPORATING A CHAMBER SYSTEM AND METHODS FOR MANUFACTURING THE CHAMBERSYSTEM, the entirety of which is hereby incorporated by reference.

In a co-molding process, an outsole first may be formed in any suitablemanner. An outsole typically may be formed from any durable material.Typically, outsole material is tough, durable, resistant to abrasion andwear, flexible, and skid-resistant. In some embodiments, polyurethanematerials sufficiently durable for ground contact may be used. Suitablethermoplastic polyurethane elastomer materials include Bayer Texin® 285,available from Bayer. Elastollan® SP9339, Elastollan® SP9324, andElastollan® C70S, available from BASF, also are suitable. Polyurethaneand other polymers that may not be sufficiently durable for directground contact may be used to form part of an outsole in someembodiments. In such embodiments, a rubber outsole may be adhered orcemented onto that part of the outsole. In some embodiments, the entireoutsole may be rubber. In embodiments, the outsole material istransparent or translucent. In embodiments, ground-engaging lugs may beintegrally formed as part of an outsole, or may be separately formed andadhered to the outsole. The outsole may have a textured ground-engagingsurface to improve traction.

An outsole then is placed in a mold that accommodates the outsole in anappropriate relationship with the corresponding component to beco-molded therewith. In some embodiments, adhesive may be applied to theappropriate surfaces of the outsole, the component, or both. Thecomponent then may be co-molded with the corresponding outsole to form aforefoot sole structure or a heel sole structure.

FIG. 41 and FIG. 42 depict a mold for co-molding forefoot component 3140with forefoot outsole 3160 with ground-engaging lugs 3135 thereon toform forefoot sole structure 3131. In some embodiments, forefoot outsole3160 wraps at least a portion of forefoot component edge 3143 onforefoot component fluid-filled chamber 3145. This forefoot outsolecompartment 3165 of forefoot outsole compartment edge 3163 that wraps atleast a portion of forefoot component edge 3143 may be used to tune thecushioning response of the forefoot sole structure 3131, as describedherein. The wrapping portion of forefoot outsole compartment edge 3163may provide additional strength and resistance to flexure at thesidewall or edge of forefoot component fluid-filled chamber 3145. Insome embodiments, forefoot outsole compartment edge 3163 wraps a shortdistance up fluid-filled chamber edge 3143. In other embodiments,forefoot outsole compartment edge 3163 wraps further up fluid-filledchamber edge 3143 to provide additional stiffness and better protectfluid-filled chamber edge 3143 from damage or wear. Forefoot solestructure 2131 is an embodiment of a forefoot sole structure havingforefoot outsole 2160 wrapping a significant portion of forefootcomponent fluid-filled chamber 2145.

FIG. 41 and FIG. 42 are cross-sectional depictions of mold 3700 forforefoot component 3140. As shown in FIG. 41 and FIG. 42, forefootcomponent 3140 is co-molded with forefoot outsole 3160 present in themold. Adhesive also may be present on appropriate portions of forefootcomponent 3140, particularly forefoot component fluid-filled chamberedges 3143 and forefoot component fluid-filled chamber lower surface3142, or to chamber-engaging surfaces of forefoot outsole 3160 that willbe in contact with forefoot component 3140.

A variety of manufacturing processes may be utilized to form forefootsole structure 3131. In some embodiments, mold 3700 that may be utilizedin the manufacturing process is depicted as including a first moldportion 3710 and a second mold portion 3720. Mold 3700 is utilized toform forefoot component 3140 from a first polymer layer 3810 and asecond polymer layer 3820, which are the polymer layers forming forefootcomponent upper surface 3141 and forefoot component lower surface 3142,respectively. More particularly, mold 3700 facilitates the manufacturingprocess by (a) shaping first polymer layer 3810 and second polymer layer3820 in areas corresponding with forefoot component fluid-filledchambers 3143, forefoot component flange 3146, and conduits betweenchambers, and (b) joining first polymer layer 3810 and second polymerlayer 3820 in areas corresponding with forefoot component flange 3146and forefoot component web area 3147.

Various surfaces or other areas of mold 3700 will now be defined for usein discussion of the manufacturing process. Referring now to FIG. 41 andFIG. 42, first mold portion 3710 includes a pinch surface 3730, a firstseam-forming surface 3740, and a compression surface 3750. Pinchsurfaces 3730 and first seam-forming surface 3740 are angled relative toeach other, with pinch surface 3730 being more vertical than firstseam-forming surface 3740. Second mold portion 3720 includes a pinchedge 3760 and a second seam-forming surface 3770. Whereas pinch edge3760 is a relatively sharp corner or angled area in second mold portion3720, second seam-forming surface 3770 extends downward and isgenerally, although not necessarily, parallel to pinch surface 3730. Avoid volume 3790 within mold 3700 and between mold portions 3710 and3720 has a shape of forefoot component 3140, prior to pressurization,and forms various features of forefoot component 3140. A portion of thisvoid volume 3790 is identified as a depression 3780 in second moldportion 3720.

Each of first polymer layer 3810 and second polymer layer 3820 areinitially located between each of first mold portion 3710 and secondmold portion 3720, which are in a spaced or open configuration, asdepicted in FIG. 41 and FIG. 42. In this position, first polymer layer3810 is positioned adjacent or closer to first mold portion 3710, andsecond polymer layer 3820 is positioned adjacent or closer to secondmold portion 3720. A shuttle frame or other device may be utilized toproperly position first polymer layer 3810 and second polymer layer3820. As part of the manufacturing process, one or both of first polymerlayer 3810 and second polymer layer 3820 are heated to a temperaturethat facilitates shaping and bonding. As an example, various radiantheaters or other devices may be utilized to heat first polymer layer3810 and second polymer layer 3820, possibly prior to being locatedbetween first mold portion 3710 and second mold portion 3720. As anotherexample, mold 3700 may be heated such that contact between mold 3700 andfirst polymer layer 3810 and second polymer layer 3820 at a later potionof the manufacturing process raises the temperature to a level thatfacilitates shaping and bonding.

Once first polymer layer 3810 and second polymer layer 3820 are properlypositioned, first mold portion 3710 and second mold portion 3720translate or otherwise move toward each other and begin to close uponfirst polymer layer 3810 and second polymer layer 3820. As first moldportion 3710 and second mold portion 3720 move toward each other,various techniques may be utilized to draw first polymer layer 3810 andsecond polymer layer 3820 against surfaces of first mold portion 3710and second mold portion 3720, thereby beginning the process of shapingfirst polymer layer 3810 and second polymer layer 3820. For example, airmay be partially evacuated from the areas between (a) first mold portion3710 and first polymer layer 3810 and (b) second mold portion 3720 andsecond polymer layer 3820. More particularly, air may be withdrawnthrough various vacuum ports in first mold portion 3710 and second moldportion 3720. By removing air, first polymer layer 3810 is drawn intocontact with the surfaces of first mold portion 3710 and second polymerlayer 3820 is drawn into contact with the surfaces of second moldportion 3720. As another example, air may be injected into the areabetween first polymer layer 3810 and second polymer layer 3820, therebyelevating the pressure between first polymer layer 3810 and secondpolymer layer 3820. During a preparatory stage of this process, aninjection needle may be located between first polymer layer 3810 andsecond polymer layer 3820, and a gas, liquid, or gel, for example, thenmay be ejected from the injection needle such that first polymer layer3810 and second polymer layer 3820 engage the surfaces of mold 3700.Each of these techniques may be used together or independently.

As first mold portion 3710 and second mold portion 3720 continue to movetoward each other, first polymer layer 3810 and second polymer layer3820 are pinched between first mold portion 3710 and second mold portion3720. More particularly, first polymer layer 3810 and second polymerlayer 3820 are compressed between pinch surface 3730 and pinch edge3760. In addition to beginning the process of separating excess portionsof first polymer layer 3810 and second polymer layer 3820 from portionsthat form forefoot component 3140, the pinching of first polymer layer3810 and second polymer layer 3820 begins the process of bonding orjoining first polymer layer 3810 and second polymer layer 3820 in thearea of forefoot component flange 3146.

Following the pinching of first polymer layer 3810 and second polymerlayer 3820, first mold portion 3710 and second mold portion 3720 proceedwith moving toward each other and into a closed configuration, asdepicted in FIG. 42. As the mold closes, pinch surface 3730 contacts andslides against a portion of second seam-forming surface 3770. Thecontact between pinch surface 3730 and second seam-forming surface 3770effectively severs excess portions of first polymer layer 3810 andsecond polymer layer 3820 from portions that form forefoot component3140. In addition, the sliding movement pushes portions of the materialforming first polymer layer 3810 and second polymer layer 3820 downwardand further into depression 3780. Moreover, the material forming firstpolymer layer 3810 and second polymer layer 3820 compacts or otherwisecollects in the area between first seam-forming surfaces 3740 and secondseam forming surface 3770. Given that first seam-forming surface 3740and second seam-forming surface 3770 are angled relative to each other,the compacted polymer material forms a generally triangular or taperedstructure, which results in forefoot component flange 3146. In additionto forming forefoot component flange 3146, first polymer layer 3810 andsecond polymer layer 3820 are (a) shaped to form forefoot componentfluid-filled chambers 3145 and (b) compressed and joined to form webarea 3147.

At the stage of the process depicted in FIG. 42, a void volume 3790,which is located between compression surface 3750 and depression 3780within mold 3700, effectively has the shape of forefoot component 3140prior to inflation or pressurization. Moreover, a peripheral portion ofthe void includes an area that forms forefoot component flange 3146between first seam-forming surface 3740 and second seam-forming surface3770. The non-parallel configuration between first seam-forming surface3740 and second seam-forming surface 3770 results in a tapered spacewhere the polymer material collects to form forefoot component flange3146. A distance across the space between first seam-forming surface3740 and second seam-forming surface 3770 is greater adjacent to aportion of the void volume 3790 that forms fluid-filled components 3145than in the area where first seam-forming surface 3740 and secondseam-forming surface 3770 meet, which is spaced from the portion of thevoid that forms forefoot component fluid-filled chambers 3145. Althoughthe configuration of the tapered space between first seam-formingsurface 3740 and second seam-forming surface 3770 may vary, an angleformed between first seam-forming surface 3740 and second seam-formingsurface 3770 may be in a range of between twenty degrees and forty-fivedegrees.

As described above, the material forming first polymer layer 3810 andsecond polymer layer 3820 compacts or otherwise collects in the areabetween first seam-forming surface 3740 and second seam-forming surface3770. This compaction effectively thickens one or both of first polymerlayer 3810 and second polymer layer 3820. That is, whereas first polymerlayer 3810 and second polymer layer 3820 have a first thickness at thestage depicted in FIG. 42, one or both of first polymer layer 3810 andsecond polymer layer 3820 within flange 3146 may have a second, greaterthickness at the stage depicted in FIG. 42. The compaction that occursas pinch surface 3730 contacts and slides against a portion of secondseam-forming surface 3770 increases the thickness of the polymermaterial forming one or both of first polymer layer 3810 and secondpolymer layer 3820.

When forming forefoot component 3140 is complete, mold 3700 is openedand forefoot structure 3131 is removed and permitted to cool. A fluidthen may be injected into forefoot component 3140 to pressurize forefootcomponent fluid-filled chambers 3145, thereby completing the manufactureof forefoot sole structure 3131. As a final step in the process,forefoot sole structure 3131 may be incorporated into a sole structureof article of footwear 2100.

FIGS. 40-42 illustrate an embodiment having relatively small overlap offorefoot outsole 3160 on forefoot component edges 3143 of forefootcomponent fluid-filled chambers 3145. FIGS. 40-42 also illustrate anembodiment in which forefoot component edges 3143 of fluid-filledchambers 3145 of forefoot component 3140 form a forefoot sole structure3131 having a continuous, smooth shape from forefoot component uppersurface 3141 to forefoot component lower surface 3142.

FIG. 43 and FIG. 44 illustrate a mold for a heel component wherein heeloutsole 3170 is placed in a mold portion in an area that is not formedto accommodate the outsole. Then, the heel component 3150 is co-moldedwith and encompasses heel outsole 3170. This technique yields a heelsole structure 3132 having heel component edges flush with heel outsoleedges.

Although a variety of manufacturing processes may be utilized, heel solestructure 3132 may be formed through a process that is generally similarto the process discussed above for forefoot component 3140 and forefootsole structure 3131. Mold 3190 that may be utilized in the manufacturingprocess is depicted as including a first mold portion 3191 and a secondmold portion 3192. Mold 3190 is utilized to form heel component 3150from additional elements of first polymer layer 3181 and second polymerlayer 3182, which are the polymer layers forming, respectively, heelcomponent upper surface and heel component lower surface. Moreparticularly, mold 3190 facilitates the manufacturing process by (a)shaping first polymer layer 3181 and second polymer layer 3182 in areascorresponding with heel component fluid-filled chamber 3155 and heelcomponent flange 3156 and (b) joining first polymer layer 3181 andsecond polymer layer 3182 in areas corresponding with heel componentflange 3156 and heel component web area 3157. In addition, mold 3190facilitates the bonding of heel outsole 3170 to heel component 3150.

Each of first polymer layer 3181 and second polymer layer 3182 isinitially located between each of first mold portion 3191 and secondmold portion 3192, as depicted in FIG. 43. In addition, one or moreelements that form outsole 3170 are also located relative to mold 3190.Once first polymer layer 3181 and second polymer layer 3182 are properlypositioned and the elements of outsole 3170 are located within voidvolume 3198 in second mold portion 3192, first mold portion 3191 andsecond mold portion 3192 translate or otherwise move toward each otherand begin to close upon first polymer layer 3181 and second polymerlayer 3182, as depicted in FIG. 44. As discussed above, air may bepartially evacuated from the areas between (a) first mold portion 3191and first polymer layer 3181 and (b) second mold portion 3192 and secondpolymer layer 3182. Additionally, fluid may be injected into the areabetween first polymer layer 3181 and second polymer layer 3182. Fluidmay be selected from the group consisting of air, liquid, gel, andblends thereof. Using one or both of these techniques, first polymerlayer 3181 and second polymer layer 3182 are induced to engage thesurfaces of mold 3190. Additionally, first polymer layer 3181 and secondpolymer layer 3182 also lay against heel outsole 3170. In effect,therefore, first polymer layer 3181 and second polymer layer 3182 areshaped against surfaces of mold 3190 and outsole 3170, as shown in FIG.44.

As first mold portion 3191 and second mold portion 3192 continue to movetoward each other, first polymer layer 3181 and second polymer layer3182 are compressed between first mold portion 3191 and second moldportion 3192, as depicted in FIG. 45. More particularly, first polymerlayer 3181 and second polymer layer 3182 are compressed to form heelcomponent flange 3156 and heel component web area 3157. Second polymerlayer 3182 also bonds with outsole 3170.

When the manufacture of heel sole structure 3132 is complete, mold 3190is opened and heel sole structure 3132 is removed and permitted to cool,as depicted in FIG. 46. A fluid then may be injected into heel component3150 to pressurize heel component fluid-filled chambers 3155, therebycompleting the manufacture of heel sole structure 3132. As a final stepin the process, heel sole structure 3132 may be incorporated into solestructure 2130 of article of footwear 2100.

As first polymer layer 3181 and second polymer layer 3182 are drawn intomold 3190, particularly the larger volumes in second mold portion 3191,first polymer layer 3181 and second polymer layer 3182 stretch toconform to the contours of mold 3190. When first polymer layer 3181 andsecond polymer layer 3182 stretch, they also thin or otherwise decreasein thickness. Accordingly, the initial thicknesses of first polymerlayer 3181 and second polymer layer 3182 may be greater than theresulting thicknesses after the manufacturing process.

FIG. 47, FIG. 48, and FIG. 49 illustrate other embodiments of heel solestructures. FIG. 47 illustrates heel sole structure 4732 including heeloutsole portions 4770. In embodiments illustrated in FIG. 47, heeloutsole portions 4770 have a first thickness at the ground-engagingarea, such as the location for traction lugs, and a second, lesserthickness on at least part of one or both vertical surfaces of heelcomponent fluid-filled chamber 4755. The thickness may be changed in agradual way, such as by a linear taper, or may be stepwise. Heel outsoleportions 4770 are thinner on the outside vertical surfaces of heelcomponent fluid-filled chamber 4755 than they are at the ground-engagingarea. In this way, the elastic response of heel sole structure 4732 maybe tuned.

FIG. 48 illustrates heel sole structure 4832 having heel outsoleportions 4870, which are thinner on both vertical surfaces of heelcomponent fluid-filled chambers 4855 than they are at theground-engaging area. In other embodiments, only the inside verticalsurfaces of heel outsole portions 4770 or 4870 may be thinned on thevertical surfaces of heel component fluid-filled chambers 4755 or 4855,respectively.

In some embodiments, any combination of such configurations may be used,thus providing additional opportunities to tune the elastic response ofthe heel sole structure.

FIG. 49 illustrates another embodiment of a heel sole structure. Heelsole structure 3932 includes heel outsole portions 3970. Heel outsoleportions 3970 extend up the interior vertical surfaces of heel componentfluid-filled chambers 3955 to heel component web area 3957. The heeloutsole portions also include a flange 3956 that extends across aportion of heel component web area 3957. This flange 3956 provides anadditional feature that can be varied to tune the elastic response ofthe heel component. Heel outsole portions 3970 extend a distance up theexterior vertical surfaces of heel component fluid-filled chambers 3955.This distance also may be varied to adjust the elastic response of theheel outsole portions.

FIG. 50 is a bottom view of an article of footwear in accordance withsome embodiments of the disclosure. FIG. 50 illustrates sole structure4130, which is secured to the lower end of an upper, such as upper 2120(FIG. 68). Sole structure 4130 is located under the foot and supportsthe foot. The primary elements of sole structure 4130 are a forefootsole structure 4131 including a forefoot component 4140 and forefootoutsole portions 4060, and a heel sole structure including a heelcomponent 4150 and a heel outsole 4070. In some embodiments, each offorefoot component 4140 and heel component 4150 may be directly securedto a lower area of upper 2120. Forefoot component 4140 and heelcomponent 4150 are formed from a polymer material that encloses a fluid,which may be a gas, liquid, or gel. During walking and running, forexample, forefoot component 4140 and heel component 4150 may compressbetween the foot and the ground, thereby attenuating ground reactionforces. That is, forefoot component 4140 and heel component 4150 areinflated and generally pressurized with the fluid to cushion the foot.

In some configurations, sole structure 4130 may include a foam layer,for example, that extends between upper 2120 and one or both of forefootcomponent 4140 and heel component 4150, or a foam element may be locatedwithin indentations in the lower areas of forefoot component 4140 andheel component 4150. In other configurations, forefoot sole structure4131 may incorporate plates, moderators, lasting elements, or motioncontrol members that further attenuate forces, enhance stability, orinfluence the motions of the foot. Heel sole structure 4132 also mayinclude such members to further attenuate forces, enhance stability, orinfluence the motions of the foot.

In addition to providing a wear surface in an article of footwear,forefoot outsole 4060 and heel outsole 4070 may enhance variousproperties and characteristics of sole structure 4130. Properties andcharacteristics of the outsoles, such as the thickness, flexibility, theproperties and characteristics of the material used to make the outsole,and stretch, may be varied or selected to modify or otherwise tune thecushioning response, compressibility, flexibility, and other propertiesand characteristics of sole structure 4130. Reinforcement of the outsole(for example, inclusion of structural elements, such as ribs),apertures, the height of the overlap, the number and location of theedges that overlap, or other features of an outsole all may be used totune the responses of the sole structure. An outsole also mayincorporate tread elements, such as protrusions, ridges, orground-engaging lugs or sections, that impart traction. In someembodiments, an outsole may be replaced by a plate or other structuralelement. A plate may have features that assist with securing an outsoleor other element to heel component 4150.

In particular, overlap of a portion of an outsole away from theground-engaging portion and up the edge of a forefoot component or aheel component, such as described above and illustrated at least in FIG.47, FIG. 48, and FIG. 49, may be used to tune the elastic response andcushioning response of the resultant sole structure. With the guidanceprovided herein, these and other properties and characteristics of theoutsole may be considered by the user in combination with the propertiesand characteristics of the fluid-filled components of the components toadjust the responses of a sole structure.

Sole structure 4130 may be translucent or transparent, and may becolored or patterned for aesthetic appeal.

Forefoot outsole 4060 is secured to lower areas of forefoot component4140. In some embodiments, forefoot sole structure 4131 may extend intoa midfoot region. The forefoot outsole 4060 also may be secured to lowerareas of forefoot component 4140 in a midfoot region. Heel outsole 4070is secured to lower areas of heel component 4150. Both heel component4150 and heel outsole 4070 may extend into a midfoot region. Forefootoutsole 4060 and heel outsole 4070 may be formed from a wear-resistantmaterial. The wear-resistant material may be transparent or translucentto provide a visually appealing effect. The wear-resistant material maybe textured on the ground-engaging portions to impart traction. In someembodiments, the wear-resistant material may have ground-engaging lugsor portions 4135, as illustrated in FIG. 50.

FIG. 51 and FIG. 52 illustrate a method of producing a sole structuresuch as but not limited to sole structure 2130 of FIGS. 33-35. FIG. 51and FIG. 52 depict a cross-section of a mold 6300 for co-molding afluid-filled chamber 5140 (from first and second polymer sheets 5410,5420) and an outsole 5160 with protuberances 5135 thereon. Thefluid-filled chamber 5140 may also be referred to as a barrier. Outsole5160 may be produced by a number of pre-formed objects or elementsassembled in the mold. In some embodiments, outsole 5160 wraps at leasta portion of edge 5143 on fluid-filled chamber 5140. The outsole 5160wraps a significant portion of the edge 5143 of fluid-filled chamber5140. As the components are produced of thermoplastic materials, theymay be softened to aid in producing the shapes in the mold.

FIG. 51 and FIG. 52 are cross-sectional depictions of the mold 6300. Asshown in FIG. 51 and FIG. 52, fluid-filled chamber 5140 is co-moldedwith outsole 5160 present in the mold. Adhesive also may be present onappropriate surfaces.

Stated generally, the co-molded article may be produced in a two-piecemold with an upper and a lower mold portion by placing outsole elementsinto the lower mold portion, then placing the layers that will form thefluid-filled chamber 5140 on top of the outsole elements. The mold isthen closed so that the upper and lower mold portions abut one another.The mold is shaped so that the closing the mold results in the formationof the chamber. Fluid under pressure is then introduced into the chamberso that the inflation of the chamber forces the upper surface of thechamber into conforming relationship with the underside of the uppermold portion, and also forces the lower portion of the chamber intoconforming relationship with the outside elements underneath. Energy maybe applied to the mold as heat, radio frequency, or the like to co-moldthe first and second elements together with the chamber inflated andpushing the article against the mold surfaces and the outsole elements.The second element portions such as layers of polymer may be provided inthe mold as a precursor for the completed product. Such precursor may beformed in the mold as part of the co-molding process as describedherein, or may be provided as completely pre-formed chamber that isready for inflation.

A variety of manufacturing processes may be utilized to produce a solestructure such as sole structure 2130. In some embodiments, mold 6300that may be utilized in the manufacturing process is depicted asincluding a first mold portion 6310 and a second mold portion 6320. Mold6300 is utilized to produce a forefoot component, also referred to as abarrier or a fluid-filled chamber 5140, from a first polymer layer 5410and a second polymer layer 5420, which are the polymer layers producingfluid-filled chamber upper surface 5141 and fluid-filled chamber lowersurface 5142, respectively. More particularly, mold 6300 facilitates themanufacturing process by (a) shaping first polymer layer 5410 and secondpolymer layer 5420 in areas corresponding with edges 5143 of thefluid-filled chambers 5140, flange 5146, and conduits between chambers,and (b) joining first polymer layer 5410 and second polymer layer 5420in areas corresponding with flange 5146 and web area 5147.

Various surfaces or other areas of mold 6300 will now be defined for usein discussion of the manufacturing process. First mold portion 6310includes a first mold portion surface 6350, which shapes the top surfaceof the co-molded article. Various parts of a first element, such asoutsole 5160, and a second element, such as a fluid-filled chamber 5140of FIG. 52, are illustrated in FIG. 51. Second mold portion 6320 isshaped so as to receive protuberances 5135 in close engagement withslots 6325 in second mold portion 6320. Outsole 5160 then is placed inthe mold. Outsole 5160 fits within undercut 6335. Then, second elementprecursor or first polymer layer 5410 is put into place to become thetop surface of the article and second element precursor or secondpolymer layer 5420 produces the bottom of the second element, herein thefluid-filled chamber, when the article is molded.

As first mold portion 6310 and second mold portion 6320 are moved towardeach other, various techniques may be utilized to draw first polymerlayer 5410 and second polymer layer 5420 against surfaces of first moldportion 6310 and second mold portion 6320, thereby beginning the processof shaping first polymer layer 5410 and second polymer layer 5420. Forexample, air may be partially evacuated from the areas between (a) firstmold portion 6310 and first polymer layer 5410 and (b) second moldportion 6320 and second polymer layer 5420. More particularly, air maybe withdrawn through various vacuum ports in first mold portion 6310 andsecond mold portion 6320. By removing air, first polymer layer 5410 isdrawn into contact with the surfaces of first mold portion 6310 andsecond polymer layer 5420 is drawn into contact with the surfaces ofsecond mold portion 6320. As another example, fluid may be injected intothe area between first polymer layer 5410 and second polymer layer 5420,thereby elevating the pressure between first polymer layer 5410 andsecond polymer layer 5420. During a preparatory stage of this process,an injection needle may be located between first polymer layer 5410 andsecond polymer layer 5420, and a fluid, such as a gas, a liquid, or agel, for example, or a blend thereof, then may be ejected from theinjection needle such that first polymer layer 5410 and second polymerlayer 5420 engage the surfaces of mold 6300. Each of these techniquesmay be used together or independently.

As first mold portion 6310 and second mold portion 6320 continue to movetoward each other, first polymer layer 5410 and second polymer layer5420 are pinched between first mold portion 6310 and second mold portion6320. More particularly, first polymer layer 5410 and second polymerlayer 5420 are compressed between pinch surface 6330 and pinch edge6360. In addition to beginning the process of separating excess portionsof first polymer layer 5410 and second polymer layer 5420 from portionsthat form fluid-filled chamber 5140, the pinching of first polymer layer5410 and second polymer layer 5420 begins the process of bonding orjoining first polymer layer 5410 and second polymer layer 5420 in thearea of flange 5146.

Following the pinching of first polymer layer 5410 and second polymerlayer 5420, first mold portion 6310 and second mold portion 6320 proceedwith moving toward each other and into a closed configuration, asdepicted in FIG. 52. As the mold closes, pinch surface 6330 contacts andslides against a portion of second seam-forming surface 6370. Thecontact between pinch surface 6330 and second seam-forming surface 6370effectively severs excess portions of first polymer layer 5410 andsecond polymer layer 5420 from portions that form fluid-filled chamber5140. The material forming first polymer layer 5410 and second polymerlayer 5420 compacts or otherwise collects to form flange 5146. Inaddition to forming flange 5146, first polymer layer 5410 and secondpolymer layer 5420 are (a) shaped to produce fluid-filled chamber 5140and (b) compressed and joined to produce web area 5147.

When producing of fluid-filled chamber 5140 with co-molded outsole 5160is complete, mold 6300 is opened. Fluid then may be injected into theforefoot component to pressurize forefoot component fluid-filledchambers 5140. The completed structure may be incorporated into anarticle of footwear.

FIGS. 53-55 show another configuration of an article of footwear 7110.Features of the article of footwear 7110 that are the same as thoseshown and described with respect to article of footwear 10 and 110 areindicated with like reference numbers. The article of footwear 7110 hasa sole structure 7130 that includes a cushioning component 7132 definingan enclosed, fluid-filled chamber 7143. As shown in FIG. 53, the solestructure 7130 also includes a unitary outsole 7160 bonded to a bottomwall 7124, to a medial sidewall 7126 (FIG. 53), and a lateral sidewall7128 (FIG. 54) of the cushioning component 7132 such that the outsole7160 wraps substantially up the side walls 7126, 7128. The outsole 7160is also bonded to a rear wall 7127 of the cushioning component 7132, asindicated in FIG. 53.

The cushioning component 7132 extends over the heel portion 13, themidfoot portion 12, and a rearward part of the forefoot portion 11. Aforefoot component 7133 is disposed forward of the cushioning component7132 in the forefoot portion 11. The forefoot component 7133 may be, byway of non-limiting example, a foam layer. The outsole 7160 extendsunder and is bonded to the forefoot component 7133 and the cushioningcomponent 7132.

As shown in FIG. 55, the outsole 7160 includes tread portions 7161 thatcan be injection molded integrally with a body portion 7170 of theunitary outsole 7160. Alternatively, the tread portions 7161 can bepositioned in a mold assembly adjacent the body portion 7170 and canthermally bond to the body portion 7170 during molding of the cushioningcomponent 7132. The tread portions 7161 may have a variety of differentshapes and patterns.

The sole structure 7130 includes an additional midsole layer 7140positioned between and secured to the cushioning component 7132 and theupper 120. The midsole layer 7140 is secured to the top wall 7122 of thecushioning component 7132.

The cushioning component 7132 may be formed from a polymer material,such as any of the polymer materials described with respect to thearticle of footwear 10. For example, in the embodiment of FIG. 53, thecushioning component 7132 includes a first polymer sheet 7181 and asecond polymer sheet 7182, which may also be referred to as an upperpolymer sheet and a lower polymer sheet, respectively. The first polymersheet 7181 is only visible in side view at the peripheral flange 7144 atwhich the first polymer sheet 7181 is bonded to the second polymer sheet7182. The second polymer sheet 7182 is bonded to the first polymer sheet7181 so that the first and second polymer sheets form the peripheralflange 7144 and define the fluid-filled chamber 7143. More specifically,with reference to FIG. 53, the first polymer sheet 7181 forms a top wall7122 of the cushioning component 7132. The second polymer sheet 7182forms a bottom wall 7124, a medial side wall 7126 and a lateral sidewall 7128 of the cushioning component 7132. The cushioning component7132 has a forefoot portion 7184, a midfoot portion 7186, and a heelportion 7188.

The first and second polymer sheets 7181, 7182 may be molded bythermoforming, as described herein, so that the peripheral flange 7144is nearer the top wall 7122 than the bottom wall 7124 as shown in FIG.53.

In one embodiment, the first and second polymer sheets 7181, 7182 aremulti-layer polymer sheets including thermoplastic polyurethane layersalternating with barrier layers that comprise a copolymer of ethyleneand vinyl alcohol (EVOH) impermeable to fluid contained in the chamber7143. The fluid may be air, nitrogen, or another gas used to inflate thechamber 7143.

As best shown in FIGS. 53 and 54, the cushioning component 7132 mayinclude a tether element 7162 within the chamber 7143. Similar to tetherelement 162 of FIG. 30, the tether element 7162 includes a first plate7163 bonded to an inner surface 7164 of the top wall 7122. The tetherelement 7162 further includes a second plate 7165 bonded to an innersurface 7166 of the bottom wall 7124. The plates 7163, 7165 may be athermoplastic material that thermally bonds to the first and secondpolymer sheets 7181, 7182 during thermoforming of the polymer sheets7181, 7182, as discussed with respect to tether element 162. The plates7163, 7165 extend through the entire cushioning component 7132, in theforefoot portion 7184, the midfoot portion 7186, and the heel portion7188. In other embodiments, the plates 7163, 7165 may extend in only oneor only two of the forefoot portion 7184, the midfoot portion 7186, andthe heel portion 7188, or multiple tether elements can be secured to thefirst and second polymer sheets 7181, 7182 within the chamber 7143.

The cushioning component 7132 also includes a plurality of tethers 7168secured to the first plate 7163 and to the second plate 7165 andextending in the fluid-filled chamber 7143 between the first plate 7163and the second plate 7165. Only some of the tethers 7168 are indictedwith a reference number in FIG. 53. The tethers 7168 are placed intension by fluid in the chamber 7143, and, because they are secured tothe plates 7163, 7165, act to control the shape of the cushioningcomponent 7132 when the chamber 7143 is filled with pressurized fluid.The tethers 7168 may be any of a variety of different configurationsincluding single strands of textile tensile members secured at each endto plates 7163, 7165, or repeatedly passing through one or both plates7163, 7165. Various configurations of tethers are shown and described inU.S. Pat. No. 8,479,412, which is hereby incorporated by reference inits entirety.

Multiple rows of tethers 7168 are present and extend across a width ofthe plates 7163, 7165 between the lateral side 14 and the medial side 15of the article of footwear 7110 included in FIG. 55. FIG. 55 shows onerow of tethers 7168. FIG. 53 shows multiple rows of tethers 7168extending laterally and positioned in the forefoot region 11, themidfoot region 12, and the heel region 13. Each tether 7168 shown in theside view of FIG. 53 is in a different row.

The outsole 7160 has a bottom portion 7142, a medial side portion 7145,and a lateral side portion 7146. The bottom portion 7142 is bonded to anouter surface of the second polymer sheet 7182 at the bottom wall 7124of the cushioning component 7132. The bottom portion 7142 of the outsole7160 extends under the bottom wall 7124 of the cushioning component 7132and under the forefoot component 7133. The medial side portion 7145 ofthe outsole 7160 is bonded to the outer surface of the second polymersheet 7182 at the medial side wall 7126 of the cushioning component7132, and the lateral side portion 7146 of the outsole 7160 is bonded tothe outer surface of the second polymer sheet 7182 at the lateral sidewall 7128 of the cushioning component 7132. The outsole 7160 has a rearwall 7149 that wraps around the rear of the heel portion 7188 of thecushioning component 7132 and is bonded to the rear wall 7127 of thecushioning component 7132.

As shown in FIG. 54, medial side portion 7145 has only one peak 7148Aand one valley 7150A. As shown in FIG. 53, lateral side portion 7146 hasonly one peak 7148B and one valley 7150B. The medial side portion 7145and the lateral side portion 7146 each form a single peak 7148A, 7148B,respectively, disposed between the midfoot portion 7186 and the heelportion 7188, and a single valley 7150A, 7150B, respectively, disposedrearward of the peak. The outsole 7160 wraps up and is bonded to therear wall 7149, forming a peak 7148C at the rear of the cushioningcomponent 7132.

Peaks 7148A, 7148B are aligned with one or more rows of the tethers7168. A peak is aligned with a row of tethers 7168 when it is positionedlaterally adjacent the row. For example, FIGS. 53 and 54 shows peaks7148A and 7148B laterally aligned with multiple rows of the tethers7168. The positioning of the peaks 7148A, 7148B relative to the rows oftethers 7168 provides lateral and medial support to the cushioningcomponent 7132. There may be fewer or more peaks and valleys than shownin the embodiment of FIGS. 53 and 54, and the peaks and valleys may havedifferent shapes than shown. The single peak 7148A is positioned at orrearward of the midfoot portion 7186, and the valley 7150A is rearwardof the single peak 7148A. The single peak 7148B is positioned at orrearward of the midfoot portion 7186, and the valley 7150B is rearwardof the single peak 7148B.

In the embodiment of FIGS. 53-55 the entire outsole 7160 issubstantially transparent. For example, the outsole 7160 may be asubstantially transparent thermoplastic polyurethane material. Thepolymer sheets 7181, 7182 can also be substantially transparent. Thisallows the tethers 7168 to be viewed through the outsole 7160 and thesecond sheet 7182. The tethers 7168 can be viewed through the outsole7160 at both the peaks 7148A, 7148B, 7148C, and the valleys 7150A,7150B. Those skilled in the art will readily understand a variety ofmethods to determine transparency of an object, such as by a test ofluminous transmittance and haze. For example, the luminous transmittanceand haze of the cushioning component 7132 and of the outsole 7160 can bedetermined according to American Society for Testing and Materials(ASTM) Standard D1003-00, Standard Test Method for Haze and LuminousTransmittance of Transparent Plastics.

While several modes for carrying out the many aspects of the presentteachings have been described in detail, those familiar with the art towhich these teachings relate will recognize various alternative aspectsfor practicing the present teachings that are within the scope of theappended claims. It is intended that all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative only and not as limiting.

What is claimed is:
 1. An article of footwear comprising: a solestructure having: a cushioning component defining an enclosed,fluid-filled chamber and having a top wall, a bottom wall, a medial sidewall at a medial side of the article of footwear, a lateral side wall ata lateral side of the article of footwear, and a rear wall at a rear ofthe article of footwear; wherein the cushioning component has a midfootportion and a heel portion rearward of the midfoot portion; a tetherelement within the fluid-filled chamber and joined to an inner surfaceof the top wall and to an inner surface of the bottom wall; and aunitary outsole having a bottom portion, a medial side portion, alateral side portion, and a rear portion; wherein the bottom portion isbonded to the bottom wall, the medial side portion is bonded to themedial side wall, the lateral side portion is bonded to the lateral sidewall, and the rear portion is bonded to the rear wall of the cushioningcomponent; wherein the medial side portion forms a single peak disposedat or rearward of the midfoot portion and a single valley disposedrearward of the single peak, the lateral side portion forms a singlepeak disposed at or rearward of the midfoot portion and a single valleydisposed rearward of the single peak of the lateral side portion, andthe rear portion forms a single peak disposed between the single valleyof the medial side portion and the single valley of the lateral sideportion.
 2. (canceled)
 3. The article of footwear of claim 1, whereinthe single peak of the medial side portion and the single peak of thelateral side portion are at least partially aligned with the tetherelement.
 4. (canceled)
 5. (canceled)
 6. (canceled)
 7. (canceled)
 8. Thearticle of footwear of claim 1, wherein the tether element includes: afirst plate bonded to the inner surface of the top wall; a second platebonded to the inner surface of the bottom wall; and a plurality oftethers secured to the first plate and to the second plate and extendingin the fluid-filled chamber between the first plate and the secondplate.
 9. The article of footwear of claim 8, wherein the fluid-filledchamber is pressurized by fluid in the fluid-filled chamber to place thetethers in tension.
 10. The article of footwear of claim 1, wherein thecushioning component is substantially transparent.
 11. The article offootwear of claim 1, wherein the outsole is a substantially transparentthermoplastic polyurethane.
 12. The article of footwear of claim 1,wherein the outsole has integral tread portions on the bottom portion.13. The article of footwear of claim 1, wherein the cushioning componentincludes: a first polymer sheet; a second polymer sheet bonded to thefirst polymer sheet so that the first and second polymer sheets form aperipheral flange and define the fluid-filled chamber; and wherein: thefirst polymer sheet includes the top wall; the second polymer sheetincludes the bottom wall, the medial side wall and the lateral sidewall; and the peripheral flange is nearer the top wall than the bottomwall.
 14. The article of footwear of claim 13, wherein: the firstpolymer sheet and the second polymer sheet are multi-layer polymersheets including thermoplastic polyurethane layers alternating withbarrier layers; and wherein the barrier layers comprise a copolymer ofethylene and vinyl alcohol (EVOH) impermeable to fluid contained in thefluid-filled chamber.
 15. The article of footwear of claim 13, furthercomprising: an additional footwear component having a bottom surface, alateral surface, and a medial surface; wherein the bottom surface issupported on the top wall of the cushioning component.
 16. (canceled)17. The article of footwear of claim 1, wherein: the bottom wall of thecushioning component has a heel portion, a midfoot portion, and aforefoot portion; and the bottom portion of the outsole extends underthe heel portion, the midfoot portion, and the bottom wall of thecushioning component, and extends forward of the forefoot portion of thebottom wall of the cushioning component.
 18. (canceled)
 19. (canceled)20. (canceled)
 21. (canceled)
 22. (canceled)
 24. (canceled) 25.(canceled)
 26. (canceled)
 27. (canceled)
 28. (canceled)
 29. The articleof footwear of claim 15, wherein the additional footwear component is anadditional midsole layer.
 30. The article of footwear of claim 29,wherein the additional midsole layer is foam.
 31. The article offootwear of claim 29, further comprising: an upper secured to theadditional midsole layer.
 32. The article of footwear of claim 31,wherein the additional midsole layer and the upper both include a heelportion, a midfoot portion, and a forefoot portion; and wherein theforefoot portion of the additional midsole layer and the forefootportion of the upper extend forward of the forefoot portion of thecushioning component.
 33. The article of footwear of claim 32, whereinthe sole structure further includes a forefoot component disposedforward of the forefoot portion of the cushioning component; wherein theoutsole is bonded to the forefoot component; and wherein the additionalmidsole layer extends over the forefoot component such that the forefootcomponent is disposed above the outsole and below the additional midsolelayer.
 34. The article of footwear of claim 1, wherein the solestructure further includes a forefoot component disposed forward of thecushioning component such that the cushioning component comprises arearward part of a forefoot portion of the sole structure and theforefoot component comprises a forward part of the forefoot portion ofthe sole structure.
 35. The article of footwear of claim 34, wherein theoutsole is bonded to the forefoot component.
 36. The article of footwearof claim 34, wherein the sole structure further includes an additionalmidsole layer having a bottom surface supported on the top wall of thecushioning component and on the forefoot component.
 37. The article offootwear of claim 36, wherein both the forefoot component and theadditional midsole layer are foam.